Catalogs > Industrial Controls Catalog > Terminal Blocks and Wiring Systems > Wiring Systems
Wiring Systems
| Introduction |  |
Standards Compliance and Certifications | |
Selecting a Wiring System | |
Catalog Number Explanation | |
1746 Digital I/O Module Selection | |
1746 Analog I/O Module Selection | |
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| Bulletin | 1762 | 1764 | 1769 |
| Features | |||
| Description | Connecting to Allen-Bradley PLC I/O modules is convenient with Allen-Bradley 1492 Wiring System Interface Modules and Cables. Unlike terminal blocks, they connect through pre-wired cables to digital base I/O of 40 I/O (i.e., cat. no. 1762-L30AWA) MicroLogix 1200. The interface modules are mounted onto a standard DIN #3 Rail. Pre-printed adhesive label cards containing field-wiring information are included for each interface module and I/O module combination. Select digital IFM wiring system modules are available for the embedded I/O of the 40 I/O MicroLogix 1200. | Connecting to Allen-Bradley PLC I/O modules is convenient with Allen-Bradley 1492 Wiring System Interface Modules and Cables. Unlike terminal blocks, they connect through pre-wired cables to digital base I/O of any MicroLogix 1500 controller. The interface modules are mounted onto a standard DIN #3 Rail. Pre-printed adhesive label cards containing field-wiring information are included for each interface module and I/O module combination. Select digital IFM wiring system modules for the base I/O of the 1764 MicroLogix 1500. | Connecting to Allen-Bradley PLC I/O modules is convenient with Allen-Bradley 1492 Wiring System Interface Modules and Cables. Unlike terminal blocks, they connect through pre-wired cables to digital and analog I/O for the Bulletin 1769 Compact I/O for CompactLogix and MicroLogix 1500. The interface modules are mounted onto a standard DIN #3 Rail. Pre-printed adhesive label cards containing field-wiring information are included for each interface module and I/O module combination. Wiring systems are available for many 1769 digital and analog I/O modules. Interposing relay modules with 10 A for M-C relays for up to 32 points are also available. |
| Product Selection | Page MicroLogix 1200 Embedded 40 I/O Controllers to IFM and Cable Selection Tables | Page Bulletin 1764, Base Units I/O and Compatible 20-Pin 1492-IFMs | Page Bulletin 1769 Compact I/O for CompactLogix and MicroLogix 1500 Controller IFM/XIMs and Cable Selection Table |
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Bulletin 1492 Programmable Controller Wiring Systems
- Increases machine building productivity
- Simplifies design and engineering time
- Reduces wiring time and wiring errors
- Benefits from quality-looking panels
Description
Connecting to Allen-Bradley I/O is convenient with Allen-Bradley Interface Modules and Cables. Unlike conventional terminal blocks, they connect through pre-wired cables to digital and analog I/O for the Bulletin 1746 SLC, Bulletin 1756 ControlLogix, Bulletin 1769 Compact I/O for CompactLogix and MicroLogix 1500, and Bulletin 1771/PLC-5 platforms. Limited solutions are also available for the MicroLogix 1200 and 1500 base I/O and for the PowerFlex 700H and 700S drives. The interface modules are mounted onto a standard DIN #3 Rail. Pre-printed adhesive label cards containing field-wiring information are available for each interface module and I/O module combination. Wiring systems are available for over 100 different I/O modules and over 50 analog modules. In addition, we offer a custom wiring system program for those applications that do not meet your system requirements.
Benefits
Reduced Wiring Time
Wiring is completed in a fraction of the time when wiring systems are used, as compared with the traditional method of wiring each point to the I/O swing arm and field-side terminal blocks. Pre-wired cables are factory-wired to the I/O wiring arm on one end and a connector for the Interface Module (IFM) on the other. IFMs enhance the capability of the I/O systems with added terminations, field-side LED status indicators, isolation circuits, overcurrent protection, and higher amperage outputs. Both standard and specific build-to-order length cables are available, providing the correct length for any panel in a neat, space-efficient wiring solution.
Reduced Wiring Errors
Wiring system cables are pre-tested to ensure 100% accurate connections and eliminate the need for point-to-point checking of wiring. No more crossed wires and loose connections between the I/O module and the terminal block. Even one error in wiring 128 I/O points in a point-to-point system may require a complete check of the wiring. Wiring errors can take several minutes to track down and correct before the panel is ready for startup. When IFMs and cables are snapped in place, they fit every time — no need to find the wrong or loose connection, resulting in a much higher rate of success at system startup.
Faster Troubleshooting and Easier Maintenance
Normal terminal blocks can’t offer the benefits of IFMs, such as LED indication on each I/O point. Wiring systems improve system startup and ease troubleshooting and maintenance. Diagnostic capabilities in the form of fuses, blown fuse indication, and field-side ON-State LEDs — in a reduced space — allow maintenance personnel to quickly locate faults, reduce downtime, and improve overall productivity.
Increased Volume and Productivity
Cable interconnections for a wiring system can be up to 30 times faster to install than traditional point-to-point wiring, enabling OEMs and panel builders using wiring systems to build panels faster and produce more machines.
Reduced Wire Preparation and Routing
Pre-wired cables eliminate the time and costs associated with stripping and cutting wires. Routing wires is much easier with wiring systems, since engineers only have to worry about routing one pre-wired cable versus the 20 or 40 wires needed in the traditional wiring method.
Labeling and Marking
Pre-printed, I/O-specific adhesive label strips for quick marking of IFM terminals save labor compared with point-to-point wiring that requires labor-intensive wire markers. Pre-wired cables require no wire labels. Pre-printed I/O-specific labels ensure neat, easy-to-read identification of wires and I/O points for all users.
The marking of traditional terminal blocks has even caused some OEMs to move toward a high-tech approach of plotting markers, requiring additional equipment in the form of a plotter system and a PC to run the plotter software.
Simplified Design
Design engineers can simplify their panel drawings by calling out an IFM and pre-wired cable instead of having to detail every single wire and terminal block on their drawings. Simplified panel drawings aid not only the installer, but also the end customer who receives the panel.
Increased DIN Rail Density
An increasing trend in the industry is to pack more products into the same DIN Rail space. Wiring systems support this trend, as they require less DIN Rail space than traditional terminal blocks. For example, if an OEM were to use a 40-point IFM in place of 40 terminal blocks, DIN Rail space can be reduced by more than 50%.
All IFMs have terminals for connecting the I/O field wiring. In addition, extra terminal, sensor, fusible, and relay IFMs contain common terminals that are used as power busses for sensor and actuators. No additional terminal blocks are needed to provide power to the sensors/actuators — saving valuable panel/DIN Rail space.
To further reduce panel space, narrow IFMs (e.g., Cat. No. 1492-IFM20FN) have been designed. They require 45% less space than the standard length IFMs, making them well-suited for tightly packed enclosures. The high density narrow IFMs have two rows of 10 field-wiring terminals with an overall length of 60 mm (2.36 in.)
Quality-Looking Panels
The pre-wired cables and IFMs organize the wiring in your panel and provide a consistent look. Pre-printed adhesive labels for the terminals neatly identify field-wiring connections, which correspond to the I/O module address. A large marking area is also available for identifying I/O information on the IFM.
Fewer Parts, Less Inventory, and Lower Carrying Cost
A wiring system involves an IFM and the cable, versus the block, barrier, jumper, markers, wires, and swing arms associated with traditional hardwired systems. Therefore, it requires fewer components and, in turn, less inventory and lower carrying costs.
Design Flexibility
To develop a cost-effective system, the hardware components must meet the needs of the design engineer. Rockwell Automation provides the broadest range of digital and analog systems in the industry. Allen-Bradley wiring wystems deliver a lower life cycle cost.
Product Overview
Digital Interface Modules (IFMs)
Digital IFMs are available with either a 20- or 40-pin cable connector. This is determined by the number of connections required for the I/O module.
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The number of terminals varies with the type of IFM — from one to four terminals per I/O point.
Standard terminal IFMs provide one field-side wiring terminal per programmable controller input or output point, as well as enough terminals for the I/O module power connections. The standard terminals are ideal for applications where the I/O device commons are terminated in the field or remotely from the I/O panel.
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Extra terminal IFMs provide two or four field-side terminals per input or output point. Non-isolated IFMs have two terminals per input or output point. Isolated IFMs have two or four terminals per input or output.
Isolated IFMs have terminals isolated into 8 or 16 groups, which allows each group of I/O devices to reference a different power source. The extra terminal IFMs are beneficial in applications where the I/O devices are terminated within the same panel as the I/O modules — eliminating the need for many additional terminal blocks.
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Sensor IFMs provide three field-side terminals per input point. The middle and lower rows of the terminals are commoned together in groups of 18, and serve as power busses for 3-wire sensor types of devices — eliminating additional terminals, blocks, and jumpering systems.
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Feed-Through Digital Interface Modules
Feed-through IFMs provided the same capability as normal terminal blocks, but in a more condensed package.
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LED-Indicating Digital Interface Modules
Voltage-indicating LEDs are available on standard, extra terminal, and sensor IFMs. The LEDs provide field-side troubleshooting diagnostics: the on/off status of an input device or the on/off status of the programmable controller output circuit. When used in conjunction with the logic-side programmable controller LEDs, the IFM LEDs can help determine whether a problem resides in the I/O module or in the field device/wiring. LED IFMs are available in both Isolated (Cat. No. 1492-IFM20DS24-4) and non-Isolated (Cat. No. 1492-IFM20D120) versions for 24V, 120V, and 240V applications.
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Fusible Digital IFMs
Fusible modules provide a convenient method of adding overcurrent protections into your programmable controller wiring. These modules have 5 x 20 fuse holders on-board and are available with and without blown fuse indication. The 24V, 120V, and 240V blown fuse indicators reduce the troubleshooting time to locate and replace a blown fuse on the IFM. Fusible modules have an easy-to-remove, transparent plexiglass cover that prevents objects from contacting fuse circuitry under normal operation. Removal of fuses from the standard fuse holder is aided by fuse pullers (fuses not provided). The fusible modules also have two or four terminals per I/O point to create a power bus for input and output load connections. Fusible modules are available in both isolated (Cat. No. 1492-IFM20F-FS24-2) and nonisolated (Cat. No.1492-IFM20F-F24-2) versions. There are a select number of fusible IFMs available for input modules.
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Relay Master/Expander XIMs Cat. No. Explanation for Digital I/O Modules
Relay master and expander XIMs are available for Bulletin 1746, 1756, 1769, and 1771 digital output modules.
Relay Master XIM — Provides 8 or 16 relay outputs for a digital output module. There are 16 relays with fusing.
Expander XIM — In addition to the relay master XIM, an expander XIM provides eight additional outputs. There are three types of expander XIMs: eight-channel relays, eight-channel fusing, and eight-channel feed-through XIMs, sixteen channel relays, sixteen channel relays with fusing.
Relay Masters
Relay Master
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Relay Master with Fusing
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Relay master XIMs feature field-replaceable relays with 120V or 24V rated coils. The field-side Form C contacts are rated 240V 10 A (de-rated to 12 A per adjacent pair on the XIM). The Form C relay output provides isolated output channels and a different voltage level from one output channel to the next. Other features include coil-side LED indicating the output module status, and transient suppression on each coil. In addition, some relay masters have 5x20 fuse holders so customers can fuse the output contacts.
Relay Expanders
Relay Expander (8 Outputs)
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Relay Expander (16 Outputs) with Fusing
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Relay expander XIMs feature field-replaceable relays with 120V or 24V rated coils. The field-side Form C contacts are rated 240V 10 A (de-rated to 12 A per adjacent pair on the XIM). The Form C relay output provides isolated output channels and a different voltage level from one output channel to the next. Other features include coil-side LED indicating the output module status, and transient suppression on each coil. In addition, a relay expander can have 5x20 fuse holders so customers can fuse the output contacts. An expander cable is provided for connection to the mating module.
Relay and Expandable Digital Interface Modules, Continued
Fusible Expanders
The fusible expander modules feature eight 5 x 20 finger-safe fuse holders, blown fuse indicators, and extra terminals for landing two wires per field-side device. They are offered with eight fuse holders for both 24V and 120V applications. An expander cable is provided for connection to its mating module.
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Feed-Through Expanders
The feed-through expander modules feature eight channels with extra terminals for landing two wires per field-side device. An expander cable is provided for connection to its mating module.
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Digital IFM Modules with Field-Removable Terminal Blocks (RTBs)
Select groups of standard, fused, and relay digital 1492 wiring system modules (refer to selection tables) have Field-Removable Terminal Blocks (RTBs). This RTB feature can provide easier wiring of field devices in a control cabinet where the IFM is located in a hard-to-reach area, or where hand-access is limited. It can also provide easier and faster replacement of a damaged or defective Bul. 1492 wiring system module. The removable plug portion of the RTB assembly has a screw at each end to securely fasten it to the RTB socket, which is mechanically secured to the module circuit board hand housing. Modules are shipped with the RTB socket, but without the removable plug(s). Plugs are available with screw-style or push-in style terminals and must be ordered separately. Refer to the selection tables for the particular PLC I/O system of interest to determine which modules are offered with field removable terminal blocks.
All of the features available on fixed terminal block products (e.g., labels, agency certification, etc.) are also provided for the removable terminal block 1492 wiring system modules.
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Digital Pre-Wired Cables
1492-Pre-wired cables are designed to minimize control wiring in a panel. Pre-wired cables, when used with an IFM, replace the point-to-point wiring between Allen-Bradley programmable controller I/O modules and individual terminal blocks. The pre-wired cables have a removable terminal block or wiring arm at the PLC end of the cable and a cable connector on the other end to connect to the IFM. All of the pre-wired cables use a #22 AWG wire and are 100% tested for continuity to make a perfect connection every time. The digital pre-wired cables are offered in four standard lengths of 0.5, 1.0, 2.5, and 5.0 m to fit a variety of applications. Other length cables are also available as build to order products. Pre-wired cables are available for many of the 1746 SLC I/O, 1756 ControlLogix I/O, 1769 Compact I/O, MicroLogix 1500 base I/O, MicroLogix 1200 (1762-L40xx) embedded I/O, and 1771 PLC-5 I/O.
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Ready-to-Wire Digital Cables
Digital I/O Ready Cable
I/O-ready cables have an I/O removable terminal block or wiring arm factory-wired to one end to of the cable and free connectors on the other end for wiring into standard terminal blocks or other type of connectors. I/O-ready cables have individual color-coded conductors for quick wire-to-terminal coordination. The I/O-ready cables use #18 AWG conductors for higher current applications or longer cable runs. The I/O-ready cables are offered in standard lengths of 1.0, 2.5, and 5.0 m to fit a variety of applications. Other cable lengths are also available as build-to-order products. Pre-wired cables are available for the Bulletin 1746 SLC I/O, Bulletin 1756 ControlLogix I/O, Bulletin 1769 Compact I/O, MicroLogix 1500 base I/O, MicroLogix 1200 (1762-L40xx) embedded I/O, and Bulletin1771 PLC-5 I/O.
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IFM-Ready Cable
IFM-ready cables have a cable connector that attached to the IFM factory wired to one end and free connectors ready to wire to I/O modules or other components on the other end. IFM-ready cables use #22 AWG wire and have individual color-coded conductors for quick wire-to-terminal coordination. The digital IFM-ready cables are offered in standard lengths of 1.0, 2.5, and 5.0 m to fit a variety of applications. Other cable lengths are also available as build-to-order products.
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Analog Interface Modules (IFMs)
Analog IFMs are available with either 15- or 25-pin D-Shell connections. This is determined by the number of connections that are required by the I/O module.
Feed-Through Analog Interface Modules
Feed-through IFMs provide the same capability as normal terminal blocks but in a more condensed package. Standard terminal IFMs provide three field-side wiring terminals per programmable controller analog input or output point, which includes enough terminals for the device shield and power connections.
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Fusible Analog Interface Modules
Fusible analog interface input modules provide a convenient method to fuse the input power source on the field side. The field-side power source is distributed through individual on-board 5 x 20 fuse holders. The AIFMs have a 24V DC blown fuse indicators to reduce the troubleshooting time required to locate and replace a blown fuse. Fusible modules have an easy-to-remove transparent plexiglass cover to prevent objects from contacting fuse circuitry under normal operation. Standard fuse holders reside in the IFM, aiding in the removal of a fuse with a fuse puller (fuses are not included). Isolation switch plugs, or “dummy fuses”, are also available to isolate an input circuit once power is removed. In addition, once the circuit has been isolated and power restored, the input loop current can be measured in 2-wire transmitter applications. The fusible modules also have three or five terminals per I/O analog input point to create a power bus for device shield and power connections.
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Fusible Analog Interface Modules, Continued
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Analog AIFM Modules with Field-Removable Terminal Blocks (RTBs)
Select groups of analog 1492 wiring system modules (refer to Selection Tables) have Field-Removable Terminal Blocks (RTBs). This RTB feature can provide easier wiring of field devices in a control cabinet where the IFM is located in a hard to reach area, or where hand-access is limited. It can also provide easier and faster replacement of a damaged or defective 1492 wiring system module. The removable plug portion of the RTB assembly has a screw at each end to securely fasten it to the RTB socket, which is mechanically secured to the module circuit board and housing. Modules are shipped with the RTB socket, but without the removable plug(s). Plugs are available with screw style or push-in style terminals and must be ordered separately. Refer to the selection tables for the particular PLC I/O system of interest to determine which modules are offered with field-removable terminals blocks.
All of the features available on analog fixed terminal block products (e.g., labels, agency certification, etc.) are also provided for the field-removable terminal block 1492 wiring system modules.
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Thermocouple Analog Interface Modules
The Cat. No.1492-AIFM6TC-3 Thermocouple IFM for the Cat. No. 1756-IT6I or -IT6I2 ControlLogix I/O module provides on-board cold junction compensation to allow thermocouples to be connected remotely while still correcting for temperature at the termination point. The combination thermistor and isothermal bar acquire temperature data at the AIFM for the thermocouple to adjust the input value.
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Analog Pre-Wired Cables
Bulletin 1492 pre-wired cables are designed to minimize control wiring in a panel. Pre-wired cables, when used with an analog IFM, replace the point-to-point wiring between Allen-Bradley programmable controller I/O modules and individual terminal blocks. The pre-wired cables have a removable terminal block or wiring arm from the PLC on one end of the cable and a D-Shell connector with a slide-locking mechanism on the other to connect to the IFM. Most pre-wired cables use twisted pairs and all have shield to aid noise immunity of the low-level analog signals. Most cables have a prepared drain wire with a ring lug at the I/O module end of the cable for convenient grounding of the cable shield to the chassis. They are 100% tested for continuity to make a perfect connection every time. The analog pre-wired cables are offered in four standard lengths of 0.5, 1.0, 2.5, and 5.0 m to fit a variety of applications. Other length cables are also available as build-to-order products. Pre-wired analog cables are available for many of the Bulletin 1746 SLC I/O, Bulletin 1756 ControlLogix I/O, Bulletin 1769 Compact I/O for MicroLogix 1500, and Bulletin 1771 PLC-5 I/O modules.