Bosch BGT PC400 Modules

Technical Dossier

Product Details And Specifications

Bosch BGT Series Technical Notes

The Bosch BGT series programmable controllers represent a generation of industrial automation hardware that achieved widespread deployment across heavy process industries — chemical plants, refineries, power generation facilities, and large-scale discrete manufacturing. The BGT PC400, as a core controller unit within this family, was engineered to handle demanding real-time control tasks in environments where system uptime is measured in years, not quarters. Installed base figures across European and Asian industrial sites remain substantial, meaning that despite the series entering its end-of-life phase, the operational demand for spare modules, replacement controllers, and compatible I/O hardware continues to be significant. For plant engineers and maintenance managers responsible for these assets, sourcing verified BGT series components is not a convenience — it is a prerequisite for avoiding forced system migrations that routinely cost seven figures.

BGT Series Full Catalog & Functionalities (SKU List)

The following represents a reference catalog of BGT series modules organized by functional category. Each entry reflects hardware that was part of the Bosch BGT ecosystem. Availability status varies — contact DriveKNMS for current RFQ confirmation.

Controllers & CPUs

• BGT PC400: Central programmable controller unit, rack-mount, real-time scan cycle execution
• BGT PC200: Compact programmable controller, reduced I/O capacity, entry-level BGT platform
• BGT PC600: High-capacity controller variant, extended memory, multi-task processing support
• BGT CPU-01: Standalone CPU module for BGT rack systems, EPROM-based program storage
• BGT CPU-02: Enhanced CPU module with expanded RAM and faster cycle time

Digital Input (DI) Modules

• BGT DI-16: 16-channel 24VDC digital input module, sink/source configurable
• BGT DI-32: 32-channel digital input module, high-density rack installation
• BGT DI-AC16: 16-channel 120/240VAC digital input module for mains-level signal acquisition

Digital Output (DO) Modules

• BGT DO-16: 16-channel 24VDC digital output module, transistor output type
• BGT DO-32: 32-channel digital output, high-density, relay or transistor output options
• BGT DO-AC16: 16-channel relay output module, 240VAC rated contacts

Analog Input (AI) Modules

• BGT AI-08: 8-channel analog input, 4–20mA / 0–10V selectable, 12-bit resolution
• BGT AI-16: 16-channel analog input module, differential input configuration

Analog Output (AO) Modules

• BGT AO-04: 4-channel analog output, 4–20mA, used for valve positioner and drive speed reference
• BGT AO-08: 8-channel analog output module, 12-bit DAC resolution

Communication & Network Adapters

• BGT CM-PB: PROFIBUS-DP communication module, BGT backplane to field network interface
• BGT CM-RS: RS-232/RS-485 serial communication module for legacy HMI and SCADA integration

Power Supply Modules

• BGT PS-24: 24VDC rack power supply module, redundancy-capable
• BGT PS-AC: AC input power supply module, 85–264VAC wide-range input

Quality Control for the BGT Series Range

BGT series hardware presents specific inspection challenges that generic electronics testing does not address. The backplane bus connectors on BGT rack systems are subject to fretting corrosion after years of thermal cycling — a failure mode that produces intermittent faults rather than hard failures, making it difficult to diagnose without targeted inspection. DriveKNMS applies a structured QC process to all BGT modules:

• Visual and mechanical inspection: Board-level examination for physical damage, capacitor bulging, and connector pin condition
• Backplane connector assessment: Pin-by-pin continuity and contact resistance measurement on all edge connectors
• Power rail verification: Confirmation that all internal voltage rails are within specification under load
• Functional power-on test: Where test fixtures are available, modules are powered and basic I/O functionality is verified
• Firmware and hardware revision logging: Hardware revision markings are recorded to ensure compatibility with the customer's existing rack configuration

Customers receive a condition report with each unit. We do not represent refurbished units as new unless they have been fully reconditioned and tested to that standard.