SCHNEIDER 140DAI54000 Discrete Input Module

I. Overview

This product is tailored for high-precision acquisition scenarios of various types of analog signals in industrial fields. Its core function is to isolate, amplify, and perform analog-to-digital conversion on various continuously changing analog signals in industrial sites (such as signals output by sensors for temperature, pressure, flow, liquid level, vibration, etc.), then accurately transmit them to Modicon Quantum series controllers, providing reliable raw data support for the controllers' operation and decision-making. It is compatible with all specifications of Modicon Quantum series controllers (such as 140CPU67160, 140CPU65160, etc.), power modules, and other I/O modules. Widely used in key industrial fields including petrochemical refining equipment, power generation unit monitoring systems, metallurgical steel rolling production lines, water treatment process control, and large pharmaceutical fermentation tank monitoring, it can achieve stable acquisition of multi-channel analog signals in harsh industrial environments such as high temperature, high humidity, and strong electromagnetic interference.

II. Technical Parameters

III. Functional Features

1. 8-Channel High-Precision Acquisition, Adapting to Multi-Type Signal Requirements

The 140DAI54000 is equipped with 8 independent differential input channels and adopts a 16-bit high-precision analog-to-digital conversion chip. The full-scale error is only ±0.05% at the rated temperature of 25℃, and the temperature drift is as low as ±0.001%FS/℃. Even within the wide temperature range of -10℃~60℃, it can still maintain extremely high acquisition accuracy. For example, in petrochemical refining equipment, when this module acquires the temperature signal of a reaction kettle (with a 4~20mA signal output by a PT100 thermal resistor + transmitter), it can control the temperature measurement error within ±0.1℃, which is far better than the industry's conventional accuracy requirement of ±0.5℃, providing reliable data support for the precise control of the reaction kettle temperature.

The module supports various industrial standard signal types, including 4~20mA, 0~20mA current signals and 0~5V, 0~10V, ±5V, ±10V voltage signals. Each channel can be independently configured with a signal type, and it can adapt to the output requirements of different sensors without replacing the module. For example, in a power generation unit monitoring system, it can simultaneously acquire: 4~20mA signals output by steam turbine bearing vibration sensors, 0~10V signals output by boiler water level transmitters, ±5V signals output by generator stator temperature sensors (via transmitters), and 0~20mA signals output by feedwater pump pressure sensors. The 8 channels can be flexibly allocated, greatly improving the flexibility of system configuration. At the same time, the module can provide 1 set of 24V DC auxiliary power for every 4 channels, which can directly power two-wire transmitters, reducing the configuration of external power modules and lowering system costs.

2. Multiple Isolation and Anti-Interference Design, Ensuring Signal Acquisition Stability

The 140DAI54000 adopts a dual electrical isolation design of "isolation between channels + isolation between channels and backplane", with an isolation voltage of 250V AC and an insulation resistance of ≥100MΩ@500V DC, which can effectively suppress common-mode interference and series-mode interference in industrial sites. In the liquid level monitoring scenario of acid-base storage tanks in chemical enterprises, sensors and modules are installed in different areas, resulting in a large ground potential difference. The isolation design of the module can avoid the interference of ground loops on signals and ensure that the liquid level signal acquisition error is ≤0.1%FS. At the same time, the module is equipped with a spike pulse suppression function, which can effectively filter instantaneous pulse interference below 2kV. When used near high-voltage equipment (such as transformers and frequency converters), it can still maintain stable signal acquisition, with a communication bit error rate of ≤0.0001%.

The module adopts an industrial-grade enhanced hardware design. The PCB board is treated with an anti-corrosion coating, which can resist the erosion of dust and oil in the industrial environment; the electronic components are military-grade products with a wide temperature range, ensuring stable operation within the operating temperature range of 0℃~60℃. In outdoor control cabinets without heating in northern winters (with temperatures as low as 0℃), the module can start normally and quickly enter a stable working state without startup delay or accuracy degradation; in high-temperature workshops in southern summers (with temperatures as high as 60℃), the module can maintain the temperature of core components ≤75℃ through an optimized heat dissipation structure design without additional cooling fans, ensuring that the analog-to-digital conversion accuracy is not affected by high temperatures.

3. Hot-Swapping and Intelligent Diagnosis, Improving Operation and Maintenance Efficiency and Reliability

The 140DAI54000 supports the hot-swapping function, which is compatible with the hot-swapping mechanism of Modicon Quantum series chassis. It can directly plug in and out the module for maintenance or replacement without stopping the control system, greatly shortening the fault handling time. In petrochemical refining equipment, if a temperature acquisition channel fails suddenly, maintenance personnel can quickly replace the standby module without interrupting the operation of the reaction kettle. Through the automatic configuration function of the controller, the module can complete parameter synchronization and resume normal operation within 500ms, avoiding production interruption caused by module replacement and reducing economic losses.

The module is equipped with a comprehensive intelligent diagnosis function, which can realize full-dimensional fault monitoring of "module-level diagnosis + channel-level diagnosis". Module-level diagnosis can real-time monitor the power voltage, backplane communication, and firmware operation status. When faults such as power overvoltage, communication interruption, and firmware abnormality occur, the red fault alarm indicator blinks, and the fault code is uploaded to the controller through the backplane bus, and the controller can link the upper computer to issue an alarm message; Channel-level diagnosis can real-time monitor the signal amplitude and wiring status of each channel. When faults such as signal overrange, wiring open circuit, and short circuit occur, the status indicator of the corresponding channel blinks, and the fault information is accurately located to the specific channel. In the water treatment process control scenario, if the wiring of a pH sensor is open, the module can detect the fault and upload the alarm information within 10ms. Maintenance personnel can directly locate the fault point according to the fault prompt, shortening the fault handling time from the traditional 1 hour to 5 minutes, and greatly improving the operation and maintenance efficiency.

4. Flexible Adaptation and Compatibility, Reducing System Integration Costs

The 140DAI54000 is perfectly compatible with all specifications of Schneider Modicon Quantum series controllers, including controllers of different performance levels such as 140CPU67160, 140CPU65160, and 140CPU63430. It can be directly connected to the system without additional adapter modules, realizing plug-and-play. At the same time, the module is compatible with various power modules (such as 140CPS11400, 140CPS12400) and chassis of the Modicon Quantum series. The system architecture can be flexibly configured according to the control scale, and it can be seamlessly adapted from small single-machine control systems (1 chassis + 1 module) to large distributed control systems (10 chassis + 50 modules). In the fermentation tank monitoring system of a pharmaceutical enterprise, only 1 140CHS11000 chassis + 1 140CPU63430 controller + 1 140DAI54000 module are needed to complete the acquisition of temperature, pressure, and pH signals of 8 fermentation tanks, reducing the system integration cost by 20%.