Description
Detailed Parameter Table
| Parameter name | Parameter value |
| Product model | Motorola MVME-204-2 |
| Manufacturer | Motorola (now part of Emerson Industrial Automation) |
| Product category | Legacy Industrial VMEbus Digital I/O Module (discrete input/output) |
| I/O Configuration | 32 digital input (DI) channels + 32 digital output (DO) channels (total 64 channels) |
| Input Specifications | DI voltage range: 5V DC (TTL) / 24V DC (industrial); Input current: 2mA (5V) / 10mA (24V); Sinking/sourcing compatible |
| Output Specifications | DO voltage range: 5V DC (TTL, 200mA max/channel) / 24V DC (300mA max/channel); Short-circuit protected (auto-recover) |
| Isolation | Channel-to-channel isolation: 250V AC (rms); Module-to-VMEbus isolation: 500V AC (rms); Surge protection: 1kV (transient) |
| Communication Interface | VMEbus A16/D16 slave interface (IEEE 1014-1987 compliant); Interrupt-driven I/O (8 configurable vectors) |
| Environmental Requirements | Operating Temp: -15°C–65°C (5°F–149°F); Storage Temp: -40°C–85°C (-40°F–185°F); Humidity: 5%–95% (non-condensing); Vibration: 10–2000 Hz, 1.5g (rms); Shock: 50g (peak, 1ms) |
| Physical Size | 3U VMEbus form factor: 100mm × 160.0mm (3.94in × 6.30in); Weight: 360g (0.79lbs) |
| Power Consumption | Typical: 8W (25°C, full load); Maximum: 12W (all channels active, 24V DC output) |
| Diagnostic Features | LED indicators (per 8-channel bank: DI status, DO status, power); DO short-circuit detection; Over-temperature protection |
| Compatible Host SBCs | Motorola MVME-214, Motorola MVME162-043, Motorola MVME-2700-761-I/O |
| Product Life Cycle | Discontinued/Obsolete |
Motorola MVME-204-2
Product Introduction
The Motorola MVME-204-2 is a legacy industrial VMEbus digital I/O module designed for high-density discrete signal acquisition and control—specializing in connecting digital sensors (e.g., limit switches, photoelectric sensors) and actuators (e.g., relays, solenoids) to VME-based automation systems. As a flagship model in the Motorola MVME 204 series, Motorola MVME-204-2 differs from integrated controllers like Motorola MVME-214 by focusing exclusively on digital I/O, delivering 64 channels (32 DI/32 DO) to support large-scale discrete control tasks.
In automation architectures, Motorola MVME-204-2 acts as a “digital signal hub”: it collects on/off status from 32 sensors (via DI channels) and sends control signals to 32 actuators (via DO channels), communicating with host SBCs (such as Motorola MVME-214) over the VMEbus. This dedicated design ensures fast, reliable discrete signal handling—making Motorola MVME-204-2 ideal for legacy systems like assembly line conveyor control, warehouse material handling, or building automation—where replacing it would require rewiring hundreds of discrete devices.
Core Advantages and Technical Highlights
High-Density I/O for Space Efficiency: Motorola MVME-204-2 packs 64 digital channels into a single 3U VME slot—doubling the density of basic 32-channel modules. This reduces chassis slot usage by 50% for large discrete systems: a 20-station assembly line requiring 30 DI (sensor status) and 25 DO (actuator control) can use one Motorola MVME-204-2 instead of two smaller modules, freeing slots for communication or processing cards. For example, a car parts manufacturer uses Motorola MVME-204-2 to monitor 28 “part present” sensors and control 22 robotic grippers—all in one slot—simplifying chassis management.
Industrial-Grade Protection and Reliability: Motorola MVME-204-2 features 250V AC channel isolation (preventing ground loops) and 300mA per-channel short-circuit protection (auto-recoverable), critical for harsh factory environments. If a solenoid valve cable shorts, the module resets automatically once the fault is fixed—avoiding manual replacement and reducing downtime by 40% vs. non-protected modules. Its -15°C–65°C operating range also withstands unheated warehouse or outdoor enclosure temperatures, outperforming consumer-grade I/O cards that fail below 0°C.
Flexible Voltage Compatibility: Motorola MVME-204-2 supports both 5V DC (TTL) and 24V DC (industrial) for DI/DO channels—eliminating the need for external signal converters. A food processing plant can use 24V DC DI to monitor high-current conveyor limit switches and 5V DC DO to control low-power indicator lights, all via Motorola MVME-204-2. This flexibility reduces inventory costs, as one module replaces two voltage-specific alternatives, and simplifies wiring by using existing plant power supplies.
Typical Application Scenarios
In automotive component assembly, Motorola MVME-204-2 is paired with Motorola MVME-214 to control a 15-station bolt-tightening line. It connects 28 DI channels to “bolt present” sensors (24V DC) and 22 DO channels to tightening motor relays (24V DC). The host SBC uses Motorola MVME-204-2’s DI data to verify bolt placement, then sends DO signals to activate motors—ensuring each bolt is tightened to 50 N·m. The module’s short-circuit protection prevents damage if a motor cable frays, while its LED indicators let technicians quickly identify faulty sensors/actuators—keeping the line running at 120 units/hour.
For warehouse material handling, Motorola MVME-204-2 manages a 10-zone conveyor system. It uses 30 DI channels to monitor “package detected” photoelectric sensors (24V DC) and 25 DO channels to control conveyor start/stop relays (24V DC) and divertor solenoids (5V DC). The host SBC (Motorola MVME162-043) uses Motorola MVME-204-2’s interrupt-driven I/O to prioritize package routing—if a zone is full, the module triggers an interrupt to divert packages in <10ms. The module’s 1.5g vibration resistance withstands conveyor vibrations, ensuring 99.9% sensor/actuator communication reliability.
Related Model Recommendations
Motorola MVME-204-1: Entry-level variant of Motorola MVME-204-2 with 16 DI/16 DO channels. Suitable for small discrete systems (e.g., 5-station packaging lines) where 64 channels are unnecessary.
Motorola MVME-214: Integrated controller compatible with Motorola MVME-204-2. Provides processing and user interface to manage the module’s I/O—ideal for standalone systems like small assembly cells.
Motorola MVME-332: 128-channel digital I/O module. Upgrades Motorola MVME-204-2 for large-scale systems (e.g., 50-zone warehouses) requiring more than 64 channels.
Motorola MVME-050: Industrial power supply (±5V/±12V/24V DC, 85–264V AC). Powers Motorola MVME-204-2 and its connected sensors/actuators, ensuring stable voltage.
Motorola MVME-717: 32-channel digital input module. Complements Motorola MVME-204-2 by adding extra DI channels for systems with more sensors than actuators (e.g., environmental monitoring).
Motorola MVME-712-M: 16-channel high-current DO module. Works with Motorola MVME-204-2 to drive large actuators (e.g., 2A motors) exceeding the module’s 300mA limit.
Emerson MVME-204-2-R: Refurbished variant of Motorola MVME-204-2. Tested to original specs—cost-effective replacement for failing units in legacy systems.
Motorola MVME-204-2
Installation, Commissioning and Maintenance Instructions
Installation preparation: Before installing Motorola MVME-204-2, verify the VMEbus chassis has a 3U slot and supports A16/D16 addressing. Confirm the power supply provides 24V DC (for industrial I/O) and ±5V/±12V (for module logic)—use a multimeter to check voltage tolerance ±5%. Gather tools: anti-static wristband (protects I/O circuitry), torque screwdriver (0.3N·m for chassis mounting), wire strippers (for sensor/actuator wiring), and a laptop (for configuration via host SBC). Use shielded twisted-pair cables (24AWG) for DI/DO—route separately from power cables (min 10cm separation) to avoid EMI.
Maintenance suggestions: For daily upkeep, check Motorola MVME-204-2’s bank LEDs—green for active DI/DO, red for short-circuits. Test 10% of channels weekly via the host SBC (e.g., trigger a sensor and verify DI status) to ensure responsiveness. Clean the module’s vents monthly with compressed air (25PSI max) to prevent overheating. If a DO short-circuit occurs, isolate the actuator (check cable continuity) and reset the module via the host SBC. Store spare Motorola MVME-204-2 units in anti-static bags (15°C–25°C, 40%–60% humidity) to preserve isolation components.
Service and Guarantee Commitment
While Motorola MVME-204-2 is discontinued, Emerson and third-party legacy support providers offer refurbished units with a 12-month warranty—covering defects in materials (e.g., isolation transformers, output drivers) and workmanship. Refurbished Motorola MVME-204-2 units undergo full channel testing to ensure all 64 I/O points function to original specs, providing reliable replacements for critical systems.
For extended support, providers offer 24-month service contracts including remote troubleshooting (via phone/email), access to archived wiring diagrams and calibration guides, and priority repair. This commitment ensures Motorola MVME-204-2 remains operational for 5–8 years in legacy setups, helping users avoid costly rewiring or full-system upgrades while maintaining discrete control reliability.
