The National Instruments 778572-12, also known as the PXI-2512, is a high-performance signal insertion switch module tailored for fault insertion applications in hardware-in-the-loop (HIL) testing and electronic reliability assessments. This module features seven channels and two fault bus lines, enabling the simulation of various fault conditions, making it particularly suitable for validating control systems such as engine control units (ECUs) and full authority digital engine controls (FADECs) using the LabVIEW Real-Time Module. Each channel supports a maximum switching voltage of 50 VDC or 30 VAC (CAT I), with a continuous current rating of 10 A per channel and a pulsed current capability of up to 50 A for a maximum duration of 600 microseconds. The module is designed to handle a maximum switching power of 500 W, with typical DC path resistance of 16 mΩ, peaking at 35 mΩ, and boasts a bandwidth exceeding 800 kHz.

For safety and reliability, the 778572-12 incorporates both overcurrent and overtemperature protection, with overcurrent detection limiting current to 10.5 A and features a response delay of 20 ms that mitigates the risk of current surges. It utilizes FET relays characterized by an operating time of 8 microseconds, with a maximum of 35 microseconds, and offers an expected unlimited lifespan under specified usage conditions. The module supports both input and output triggers through PXI trigger lines 0 to 7, with a minimum input pulse width of 150 ns and software-selectable output pulse width ranging from 1 µs to 62 µs. The device is outfitted with two DSUB connectors, each containing eight positions, and fits within a compact 3U, two-slot PXI or cPCI module. Compatible with PXI Express, the module requires 1.0 W at 3.3 V and 13.0 W at 5 V from a PXI chassis, or 14.7 W at +12 V and 1.4 W at 3.3 V from a PXI Express chassis.

Operating in a temperature range of 0 °C to 50 °C and capable of storage between -40 °C and 70 °C, the 778572-12 maintains functionality at relative humidity levels of 5% to 85% and altitudes up to 2,000 meters. This module complies with a range of CE, safety, and EMC standards, ensuring reliability and performance in demanding environments.