B&R System 2005 Modules | 3AI775.6 Analog Input Module

Technical Dossier

Product Details And Specifications

B&R System 2005 Series: Comprehensive Module Range and Technical Overview

The B&R System 2005 is a modular programmable controller platform developed by Bernecker & Rainer Industrie-Elektronik GmbH (Austria). It achieved widespread deployment across global heavy industry sectors including petrochemical refining, nuclear auxiliary systems, pulp and paper processing, and continuous casting in steel mills. Its backplane-based architecture, deterministic scan cycle, and robust I/O density made it a preferred platform for process automation engineers throughout the 1990s and into the 2000s. Installed base units remain operational in facilities across Europe, Asia, and the Americas, creating sustained demand for spare parts and replacement modules.

The Evolution of System 2005 Architecture

B&R System 2005 was introduced as a successor to earlier B&R controller generations, offering a structured rack-and-slot architecture with a proprietary backplane bus. The CPU modules communicated with I/O modules via a parallel backplane, with cycle times configurable down to 1 ms for time-critical tasks. Early revisions used EPROM-based program storage; later revisions introduced battery-backed SRAM and Flash memory options. The system supported both standalone rack configurations and distributed I/O via the B&R ETHERNET Powerlink and proprietary fieldbus adapters. As the platform matured, B&R introduced the System 2010 and subsequently the X20 System as architectural successors, rendering System 2005 a legacy platform. Migration paths exist from System 2005 to X20, but hardware-level compatibility requires adapter backplanes and updated software projects in B&R Automation Studio. For facilities that cannot undertake full migration, long-term spare parts sourcing remains the primary maintenance strategy.

System 2005 Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly sourced modules within the B&R System 2005 platform. Modules are classified by functional category.

Analog Input Modules (AI)

• 3AI775.6: 6-channel analog input module, ±10 V / 0–20 mA, 12-bit resolution, System 2005 backplane
• 3AI776.6: 6-channel analog input, high-resolution 14-bit, configurable input ranges per channel
• 3AI777.6: 6-channel analog input with HART protocol support for smart field device integration
• 3AI778.6: 6-channel thermocouple/RTD input module, supports PT100, PT1000, J, K, T types

Analog Output Modules (AO)

• 3AO355.6: 4-channel analog output, 0–10 V / 4–20 mA, 12-bit DAC resolution
• 3AO356.6: 4-channel analog output, 14-bit resolution, short-circuit protected outputs

Digital Input Modules (DI)

• 3DI196.6: 32-channel digital input, 24 VDC, sink/source configurable, LED status per channel
• 3DI197.6: 16-channel digital input, 120 VAC, optically isolated, DIN rail mount
• 3DI198.6: 32-channel digital input, 48 VDC, high-density I/O for space-constrained racks

Digital Output Modules (DO)

• 3DO196.6: 32-channel digital output, 24 VDC, 0.5 A per channel, transistor output
• 3DO197.6: 16-channel relay output, 250 VAC / 2 A per channel, Form C contacts
• 3DO198.6: 32-channel digital output, 24 VDC, 0.5 A, with diagnostic short-circuit detection

CPU / Controller Modules

• 3CP474.60-1: System 2005 CPU module, 80486 processor, 512 KB SRAM, RS-232/RS-485 onboard
• 3CP476.60-1: Enhanced CPU, 1 MB SRAM, Ethernet interface, Automation Studio compatible
• 3CP478.60-1: High-performance CPU, 2 MB Flash, dual serial ports, real-time clock

Communication & Fieldbus Adapters

• 3IF661.6: PROFIBUS-DP slave adapter, 12 Mbit/s, GSD file configurable
• 3IF662.6: DeviceNet adapter module, 500 kbit/s, EDS file supported

Power Supply Modules

• 3PS465.6: System 2005 rack power supply, 24 VDC input, 5 VDC / 10 A backplane output
• 3PS466.6: Redundant power supply module, hot-swap capable, status relay output

Sourcing Hard-to-Find & Obsolete System 2005 Parts

B&R officially discontinued active production of System 2005 hardware. The platform is classified as End-of-Life (EOL), with no new manufacturing orders accepted through standard distribution channels. DriveKNMS maintains a dedicated inventory of tested System 2005 modules sourced from decommissioned plant equipment, authorized surplus channels, and controlled factory stock. For facilities operating System 2005 installations with planned operational lifespans extending beyond 2030, DriveKNMS provides lifecycle extension support including: module-level replacement sourcing, cross-reference to compatible substitute part numbers where applicable, and bulk reserve stock agreements for critical spare parts. Customers in the petrochemical and power generation sectors with long maintenance intervals particularly benefit from pre-negotiated buffer stock arrangements.

Quality Control for the System 2005 Range

System 2005 modules present specific testing challenges due to their backplane bus architecture and proprietary communication protocol. DriveKNMS applies the following verification procedures to all System 2005 inventory prior to dispatch: (1) Visual inspection for capacitor aging, PCB corrosion, and connector pin integrity. (2) Powered functional test using a System 2005 test rack with a known-good CPU module, verifying backplane communication handshake and module self-diagnostics. (3) For analog input modules including the 3AI775.6: calibration verification across all 6 channels using a precision signal source (±10 V and 4–20 mA ranges), with measurement accuracy confirmed against factory specification of ±0.1% full scale. (4) For digital I/O modules: channel-by-channel switching test under rated load conditions. (5) Burn-in period of minimum 24 hours at operating temperature before final packaging. All modules are shipped with a test report and 12-month warranty against functional defects.