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Description
Description
The Industrial ZMI-2002 is a high-performance dual-channel signal isolator and transmitter,engineered to solve signal interference and ground loop issues in industrial automation systems.As a critical component in signal transmission chains,it isolates,conditions,and converts analog signals(such as 4-20mA current or 0-10V voltage)from field sensors(temperature,pressure,flow sensors)to stable,noise-free signals for PLCs,DCSs,or SCADA systems.
Equipped with advanced magnetic isolation technology,the ZMI-2002 provides 2500Vrms electrical isolation between input,output,and power supply,effectively blocking electromagnetic interference(EMI)and radio frequency interference(RFI)common in industrial environments.It supports dual-channel independent operation,allowing simultaneous processing of two separate sensor signals,and offers flexible signal conversion(e.g.,4-20mA to 4-20mA,0-10V to 4-20mA).With a wide operating temperature range(-25℃~+70℃)and DIN rail mount design,it is widely used in chemicals,power generation,oil refining,and manufacturing—where reliable,accurate signal transmission is essential for process control and safety.
Application Scenarios
Imagine a medium-sized steel mill with 10 temperature sensors(outputting 4-20mA)installed near high-power motors.Previously,the mill faced severe signal interference,with sensor data fluctuating by±1.5mA—leading to inaccurate furnace temperature control and 6%higher energy consumption.After installing the Industrial ZMI-2002 between the sensors and the mill’s DCS,the module’s 2500Vrms isolation blocked EMI from the motors,reducing signal fluctuation to±0.05mA.
During a peak production shift,a temperature sensor near a rolling mill experienced a sudden voltage surge.The ZMI-2002’s built-in overload protection immediately cut off the abnormal signal,preventing damage to the DCS input card and avoiding a 2-hour furnace shutdown.Additionally,the module’s dual-channel design allowed the mill to monitor two sensors with one unit,reducing installation space by 50%compared to single-channel isolators.This scenario demonstrates how the ZMI-2002 solves key industry pain points:signal interference,equipment damage from surges,and space inefficiency in multi-sensor setups.
Parameter
Main Parameters
Value/Description
Product Model
Industrial ZMI-2002
Product Category
Dual-channel industrial signal isolator/transmitter/converter
Input Signal Types
4-20mA DC current,0-10V DC voltage(selectable per channel)
Output Signal Types
4-20mA DC current,0-10V DC voltage(configurable per channel;dual-output optional)
Isolation Level
2500Vrms(input-output),2500Vrms(input-power),2500Vrms(output-power)
Measurement Accuracy
±0.1%of full scale(at 25℃ambient temperature)
Linear Error
≤±0.05%of full scale
Response Time
≤10ms(90%step response)
Power Supply
AC 85-265V/DC 12-36V(wide-range power supply,auto-adaptive)
Power Consumption
≤3W per module(dual-channel operation)
Operating Temperature
-25℃~+70℃(operating);-40℃~+85℃(storage)
Storage Humidity
5%~95%RH(non-condensing)
Protection Rating
IP20(for DIN rail mounting in control cabinets)
Physical Dimensions
18mm×110mm×120mm(W×H×D);DIN rail 35mm compatible
Weight
Approximately 120g
Certifications
CE,UL 508C,IEC 61010-1,RoHS
Protection Functions
Overload protection(input/output),short-circuit protection,over-temperature protection
Mounting Method
DIN rail mounting(35mm standard);no additional tools required
Channel Configuration
Dual-channel independent operation;each channel supports separate signal types
Technical Principles and Innovative Values
Innovation Point 1:Triple-Isolation Design
Unlike basic isolators with only input-output isolation,the ZMI-2002 features 2500Vrms triple isolation(input-output,input-power,output-power),eliminating ground loops and EMI from all paths.A chemical plant using this module reported a 90%reduction in signal noise compared to single-isolation isolators,improving process control accuracy by 15%.
Innovation Point 2:Dual-Channel Flexibility
Each channel of the ZMI-2002 can be independently configured for different signal types(e.g.,Channel 1:4-20mA input/4-20mA output;Channel 2:0-10V input/4-20mA output).This eliminates the need to stock multiple single-channel isolators.A pharmaceutical plant reduced spare parts inventory by 60%and installation costs by$1,200 per control panel by standardizing on the ZMI-2002.
Innovation Point 3:Wide-Range Power Supply
With AC 85-265V/DC 12-36V auto-adaptive power supply,the module works in global industrial power environments without voltage conversion.A multinational manufacturing company used the ZMI-2002 across its plants in Europe(230V AC)and Asia(220V AC/24V DC),avoiding the cost of region-specific power modules.
Innovation Point 4:Predictive Overload Protection
Beyond basic short-circuit protection,the ZMI-2002 monitors input/output current/voltage in real time.When signals exceed 120%of full scale,it triggers a temporary shutdown and alerts operators via a status LED—preventing damage to downstream PLC/DCS cards.A power plant used this feature to avoid 3 DCS card replacements annually,saving$4,500 per replacement.
Application Cases and Industry Value
Case 1:Chemical Plant Sensor Signal Isolation
A large chemical plant with 20 pressure sensors(4-20mA output)faced severe ground loop issues,causing signal drift of±0.8mA and inconsistent reactor pressure control.Installing 10 Industrial ZMI-2002 modules(each handling two sensors)eliminated ground loops via 2500Vrms isolation,reducing signal drift to±0.03mA.
The modules’accurate signal transmission allowed the DCS to optimize reactor pressure within±0.05MPa,reducing raw material waste by 8%.Over one year,this translated to
120,000incostsavings.Additionally,the∗∗ZMI−2002∗∗’sover−temperatureprotectiondetectedafailingsensor(overheatingto65℃)andshutdownthesignal,preventingareactoroverpressureincidentthatcouldhavecost
500,000 in equipment damage.
Case 2:Power Plant Instrumentation Signal Conversion
A 300MW coal-fired power plant needed to convert 0-10V voltage signals from 15 flow meters to 4-20mA current signals for its DCS(which only accepted 4-20mA).Deploying 8 Industrial ZMI-2002 modules(dual-channel)enabled seamless signal conversion,avoiding the need to replace the existing flow meters.
The module’s anti-EMI design ensured stable signal transmission near the plant’s high-voltage transformers,with signal error rates dropping from 7%to 0.1%.The plant’s maintenance team also benefited from the module’s DIN rail mount design,reducing installation time by 40%compared to panel-mounted isolators.Over 12 months,the solution saved$80,000 in meter replacement costs and improved DCS data accuracy by 20%.
Related Product Combination Solutions
Industrial 4-20mA Pressure Sensor(PS-420):Pair with ZMI-2002 for pressure signal isolation,ideal for chemical reactor pressure monitoring.
PLC(e.g.,Siemens S7-1200):Connect to ZMI-2002’s output for stable signal reception,ensuring accurate PLC-based process control.
DCS(e.g.,ABB AC 800M):Integrate with ZMI-2002 to eliminate signal interference in large-scale process automation systems.
DIN Rail Power Supply(PS-DIN-24V):Provide stable 24V DC power to ZMI-2002,suitable for industrial control cabinets.
Signal Cable(Shielded Twisted-Pair):Use with ZMI-2002 to further reduce EMI,recommended for long-distance signal transmission(up to 1km).
SCADA Software(e.g.,Wonderware Intouch):Receive conditioned signals from ZMI-2002 for real-time process monitoring and data logging.
Temperature Transmitter(TT-420):Output 4-20mA temperature signals to ZMI-2002 for isolation,perfect for steel mill furnace temperature monitoring.
Industrial HMI(e.g.,Allen-Bradley PanelView):Display signals processed by ZMI-2002,enabling operators to monitor and adjust process parameters intuitively.
Installation,Maintenance,and Full-Cycle Support
Installation Preparation:Mount the Industrial ZMI-2002 on a standard 35mm DIN rail in the control cabinet,ensuring at least 5mm clearance between adjacent modules for ventilation.Connect the power supply(AC 85-265V or DC 12-36V)to the designated terminals,verifying polarity to prevent damage.Wire field sensor signals to the input terminals and PLC/DCS to the output terminals—use shielded twisted-pair cables(22-18 AWG)and ground the cable shield at both ends to minimize EMI.Use the module’s DIP switches to configure input/output signal types(4-20mA/0-10V)per channel before powering on.
Maintenance and Troubleshooting:Perform quarterly visual inspections to check the module’s status LED(green=normal,red=fault)and terminal block tightness.Every 6 months,use a precision signal generator to calibrate the module and ensure±0.1%accuracy.If a fault occurs:1)Check the power supply voltage to confirm it’s within the 85-265V AC/12-36V DC range;2)Disconnect the input signal and test the module with a standard 4-20mA/0-10V signal to isolate sensor vs.module issues;3)Inspect output wiring for short circuits using a multimeter.The ZMI-2002’s self-diagnostic LED reduces troubleshooting time by 70%compared to non-indicating isolators.
Full-Cycle Support:We offer a 2-year standard warranty for the Industrial ZMI-2002,with optional 3-year extensions covering manufacturing defects and performance issues.Our global technical team provides 24/7 remote support—including configuration guidance,calibration assistance,and fault resolution—with average response times under 1 hour.For large-scale projects(e.g.,chemical plant expansions),we deploy on-site engineers to assist with installation,commissioning,and operator training.We maintain a global inventory of spare modules,ensuring delivery within 48 hours to minimize downtime.
Whether you’re solving signal interference in power plants,converting signals for PLC/DCS integration,or isolating sensor signals in chemical processes,the Industrial ZMI-2002 delivers unmatched stability,flexibility,and reliability.Contact us today to discuss your signal isolation requirements and receive a customized solution proposal tailored to your industry needs!
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