Case Study: When a Packaging Line Needed Flexible High-Count Relay Outputs
A mid-sized food packaging plant was upgrading its control panel. The existing 8-channel relay cards could not handle the mix of 24 V DC solenoid valves and 240 V AC indicator lamps on the new line. They needed a single module that could switch both voltage types without external interposing relays. The Schneider BMXDRA1605 solved this problem. As a Modicon X80 discrete output module, it provides 16 normally-open relay outputs. Each channel handles 24 to 240 V AC or 24 to 48 V DC, directly driving diverse field devices. This eliminated extra components and simplified wiring.
What Is the BMXDRA1605?
The BMXDRA1605 is a discrete output module from Schneider Electric’s Modicon X80 range. It offers 16 relay outputs, each conforming to EN/IEC 61131-2. The module suits control systems that require high channel count and mixed voltage switching. Its compact design and 0.15 kg weight make it easy to install in tight cabinets. The module operates on 24 V DC backplane power and draws 95 mA at 24 V DC typical.
Key Technical Specifications
| Specification | Value |
|---|---|
| Product or component type | Discrete output module |
| Range of product | Modicon X80 |
| Discrete output number | 16 |
| Discrete output type | Relay |
| Discrete output voltage | 24…48 V DC (19…60 V DC); 24…240 V AC (19…264 V AC) |
| [Ith] conventional free air thermal current | 2 A |
| Response time on output | < 8 ms activation; < 10 ms deactivation |
| Typical current consumption | 100 mA at 3.3 V DC; 95 mA at 24 V DC |
| Output overload protection | Use 1 fast blow fuse per channel or group of channels |
| Output overvoltage protection | Use discharge diode on each output DC; RC circuit or ZNO surge limiter on each output AC |
| Output short-circuit protection | Use 1 fast blow fuse per channel or group of channels |
| Minimum switching current | 1 mA at 5 V DC |
| Insulation resistance | > 10 MOhm at 500 V DC |
| Power dissipation | 3 W |
| MTBF reliability | 2,100,000 hours |
| Status LED | 1 green RUN; 1 green per channel; 1 red ERR; 1 red I/O |
| Product weight | 0.15 kg |
| IP degree of protection | IP20 |
| Dielectric strength | 2000 V AC at 50/60 Hz for 1 minute |
| Vibration resistance | 3 gn |
| Shock resistance | 30 gn |
| Ambient air temperature for operation | 0…60 °C |
| Ambient air temperature for storage | -40…85 °C |
| Relative humidity | 5…95 % at 55 °C without condensation |
| Operating altitude | 0…2000 m (2000…5000 m with derating) |
Why the BMXDRA1605 Excels in Demanding Applications
The 16 relay outputs allow direct control of high-power loads. The wide voltage range covers both low-voltage DC signals and standard AC control circuits. The 2 A thermal current per channel supports many industrial actuators. The fast response time under 8 ms ensures quick switching for time-sensitive processes. The module includes per-channel diagnostics via green LEDs, simplifying troubleshooting. With a MTBF of 2.1 million hours, it delivers exceptional reliability.
Installation and Setup
Mount the module on a Modicon X80 backplane. Ensure the power supply meets the 24 V DC requirement. For output protection, install a fast-blow fuse on each channel or group. For DC outputs, use a discharge diode; for AC outputs, use an RC circuit or ZNO surge limiter. Maintain proper clearance for air circulation. The IP20 rating requires installation inside a protective enclosure. Connect field wiring according to local codes and the manufacturer’s guidelines.
Maintenance and Reliability
Periodic inspection of relay contacts is recommended. Check for wear or pitting, especially in high-cycle applications. Verify that fuses are intact and properly rated. Keep the module free from dust and moisture. The wide operating temperature range (0…60 °C) suits most industrial environments. The high MTBF reduces unplanned downtime. For safety-related applications, always follow the manufacturer’s safety manual and perform regular functional tests.
Compatibility and Integration
The BMXDRA1605 integrates seamlessly with Modicon X80 PLC systems. It communicates via the backplane, requiring no external network configuration. This makes it a drop-in solution for existing X80 installations. The module works with a variety of field devices, including solenoids, contactors, and indicator lights. Its relay outputs are compatible with both AC and DC loads, providing design flexibility.
Selection Guide
Before purchasing, verify that your system uses the Modicon X80 platform. Confirm the required number of outputs and voltage types. Check that the 2 A per channel rating meets your load requirements. Consider the operating temperature and environmental conditions. For reliable supply and expert support, visit SpareTechPLC. They offer genuine Schneider components and technical assistance.
Frequently Asked Questions
1. Can the BMXDRA1605 switch both AC and DC loads on the same module?
Yes. Each relay output supports 24…240 V AC or 24…48 V DC. You can mix load types across channels.
2. What is the maximum current per output channel?
The conventional free air thermal current is 2 A per channel. However, you must provide external fusing for overload and short-circuit protection.
3. Does this module require external protection components?
Yes. Use a fast-blow fuse per channel or group. For DC outputs, add a discharge diode. For AC outputs, use an RC circuit or ZNO surge limiter.
4. What is the response time of the relay outputs?
Activation is less than 8 ms; deactivation is less than 10 ms.
5. Is the BMXDRA1605 suitable for safety functions?
This is a standard discrete output module. For safety-related applications, consult the manufacturer’s safety manual and use appropriate safety-rated devices.
