B&R 3DM486.6 Digital Mixed I/O Module

Basic Information

Model：3DM486.6

Brand: B&R Automation

Product Family: System 2005 (Legacy PCC Backplane System)

Module Type: Digital Mixed I/O Module

⚠️ Status: Manufacturer Discontinued (Obsolete). Only stock and second-hand spare parts available. New projects are recommended to migrate to the X20 series.

2. Core Channel Specifications

3. Electrical & Environmental Specifications
4. Power Consumption

Backplane 5 V: 1.2 W

Field 24 V supply: 2.2 W

2. Protection Features

Thermal shutdown upon output short-circuit, inductive load protection, external supply reverse polarity protection

3. Environmental Conditions

Operating Temperature: 0 ~ +60 °C

Storage & Transport Temperature: -25 ~ +70 °C

Relative Humidity: 5%～95 %, non-condensing

Protection Class: IP20 (for cabinet mounting only)

4. Mechanical Specifications

System 2005 single-width module

Weight: approx. 0.32 kg

4. Mandatory Terminals (Not included with module, order separately)

The module is equipped with sockets; terminal blocks must be ordered separately. 2 pcs of 18-pin terminals required

7TB718.9: Screw terminal block, 1.5 mm²

7TB718.91: Cage Clamp spring terminal block, 1.5 mm²

X1 connector: DO1~DO16; X2 connector: DI1~DI16

5. Software Compatibility

Minimum supported Automation Studio version: V2.6

Corresponding hardware upgrade package required: V1.0.1.0

6. Replacement Options (Key Information)

1) Drop-in compatible within the same platform (Retain System2005 backplane & CPU)

No direct pin-to-pin upgraded model. Similar reference within series:

3DM476.6: 16DI + 16DO, supports DC/AC24 V inputs (different electrical characteristics for selection)

2) Platform Migration (New projects / complete cabinet retrofit, System2005 → X20)

Functionally equivalent combination:

X20DI9371 (16DI) + X20DO9322 (16DO)

Advantages: Stable long-term availability, sufficient stock, enhanced diagnostic functions.

7. Typical Applications

Packaging machinery, textile equipment, printing presses, legacy production line retrofits; used for signal acquisition from proximity switches and pushbuttons, and driving small loads such as solenoid valves and indicator lamps.

⚠️ Selection & Maintenance Precautions

1. Output is Sourcing type (PNP). Connect load negative terminal to 0 V; cannot be directly wired for sinking drive.
2. Do not exceed 0.5 A continuous current per channel; total module output current must not exceed 8 A.
3. Freewheeling diodes must be wired in parallel for inductive loads (solenoid valves).
4. System2005 backplane modules cannot be plugged directly into X20 bases; backplane bus protocols are incompatible.
5. When purchasing discontinued spare parts, distinguish refurbished / used / brand-new surplus stock and confirm warranty terms.

If required, I can provide:

1) Complete terminal pin assignment table

2) Standard DI/DO wiring schematic

3) Configuration key points for Automation Studio hardware setup

B&R 3DM486.6 Hardware Installation Manual (Field Version)

Product Platform: B&R System 2005 PCC

Module Type: 16DI / 16DO Digital Mixed I/O Module

Status: Manufacturer discontinued, for spare part use only

Scope: Cabinet assembly, wiring, power-on commissioning, troubleshooting

Table of Contents

1. Safety Instructions
2. Product & Accessory List
3. Mechanical Installation (Backplane Mounting Procedure)
4. Complete Terminal Pin Assignment
5. Electrical Wiring Specifications (DI/DO Schematic)
6. Environmental & Mounting Dimensions
7. Power-on Inspection & LED Indicator Definition
8. Automation Studio Configuration Guidelines
9. Operational Restrictions & Common Faults
10. Upgrade & Replacement Guidance
11. Mandatory Safety Instructions
12. Module insertion / removal must be performed with power disconnected! Hot-plugging System2005 backplane modules is strictly prohibited; it may permanently damage backplane bus interfaces.
13. Implement ESD protection before handling; wear anti-static wrist strap. Circuit boards are sensitive to electrostatic discharge.
14. Fuses must be installed for external 24 VDC power supply; reverse polarity of power supply is forbidden.
15. Freewheeling diodes must be fitted in parallel to inductive loads (solenoid valves, contactors) driven by output channels.
16. Module protection rating IP20, installation inside control cabinet only. Do not expose directly to dust or moisture.
17. Galvanic isolation exists between DI bank and DO bank; no channel-to-channel isolation. Separate low-level I/O cables from power cables during wiring.
18. Module & Mandatory Accessories

Main Module

Model: 3DM486.6

Channels: 16×DI (24 VDC Sink/Source) + 16×DO (24 VDC Sourcing transistor output, 0.5 A per channel)

Terminals to be ordered separately (Not supplied with module)

7TB718.9: 18-pin screw terminal block, max conductor cross-section 1.5 mm²

7TB718.91: 18-pin Cage Clamp spring terminal block, max conductor cross-section 1.5 mm²

Quantity required: 2 terminal blocks (X1 for DO, X2 for DI)

3. Mechanical Installation Steps for System2005 Backplane
4. Confirm complete power-off of the entire PCC rack; isolate the power supply module from mains.
5. Align the bottom guide slots of the module with the DIN rail backplane guides and slide horizontally into the slot.
6. Press the side latches inward until an audible click confirms the module is locked to the backplane.
7. Verify the rear gold-plated bus connector is fully seated against the backplane connector without tilting or gaps.

⚠️ Do not pry the module with screwdrivers. To remove, release side latches and pull the module out parallel to the backplane.

5. Vertically insert the 7TB718 terminal plugs into the lower X1 and X2 sockets of the module until fully engaged.

Mounting Clearance Requirements

Maintain minimum 25 mm ventilation space above and below each module;

Operating ambient temperature 0 ℃ ~ +60 ℃. Implement cabinet temperature reduction if operating continuously above 55 ℃.

4. Complete Terminal Pin Assignment

X1 = Output Terminal (DO1~DO16)

X2 = Input Terminal (DI1~DI16)

X1 (DO Output, 18 Pin)

✅ Output Type: Sourcing / PNP Output

When DO is activated, +24 V is present on DO pin. Connect one terminal of load to DO, the other terminal to 0 V.

X2 (DI Input, 18 Pin)

Two DI Wiring Configurations

1. PNP Sensor (Sourcing Type)

Sensor positive → DI channel; Sensor negative → 0 V; Connect module X2.18 to field 0 V

2. NPN Sensor (Sinking Type)

Sensor positive connected to 24 V; Sensor output → DI channel; Connect module X2.17 to field +24 V

Input hardware filter: Fixed at 1 ms, non-adjustable via software.

5. Electrical Ratings

Backplane 5 V power draw: 1.2 W

Field 24 V power draw: 2.2 W

Maximum continuous per-channel output: 0.5 A DC24 V

Global module output current limit: 8 A; prolonged overload not permitted

Isolation: Galvanic isolation between DI bank and DO bank; no isolation between individual channels

Protection: Thermal shutdown for output short-circuit, reverse polarity protection

6. Module Dimensions (mm)

Width: 25 (System2005 single-width module)

Height: 130

Depth: 86

Weight: approx. 320 g

7. LED Indicator Definition

One LED assigned per channel on module front face:

DI LED ON: High level detected on corresponding input channel

DO LED ON: Output enabled in program and hardware output switched ON

Power status: Standby LEDs illuminated when backplane supply is normal; no LED response upon backplane communication failure.

8. Automation Studio Hardware Configuration Guidelines
9. Minimum supported AS version: V2.6 and above
10. Hardware library selection: `3DM486.6` System 2005 DM module
11. Address mapping: Follow rack slot sequence; slot numbering starts from CPU and extends backward
12. Diagnostics support: Software readable faults for output short-circuit and overload

Important: Cannot be installed directly onto X20 backplane; bus protocols are incompatible!

9. Fault Troubleshooting Matrix

10. Retrofit & Replacement Guidance

Same Platform Compatibility (No CPU/Backplane Modification)

Similar model: 3DM476.6 (Supports AC24 V inputs; pin assignment differs, wiring modification required)

Platform Upgrade System2005 → X20 (Recommended for New Projects)

Functionally equivalent combination:

X20DI9371 (16DI) + X20DO9322 (16DO)

Advantages: Long-term production availability, stable spare part supply, enhanced diagnostic capability.

11. Wiring Engineering Specifications
12. Separate I/O signal cables from power cables, minimum separation distance ≥30 cm; use shielded cables if separation cannot be achieved.
13. Install independent fuses for all 24 VDC circuits (3~5 A recommended rating).
14. Implement single-point earthing inside control cabinet; reliably connect signal ground and protective earth.
15. Recommended cable cross-section: 0.75~1.0 mm².