Wiring Systems

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Introduction Digital Interface Modules (IFMs) Digital Interface Modules (XIMs)
Digital Relay Expanders Digital Cables Analog Interface Modules (AIFMs)
Analog Pre-Wired Cables Standards Compliance and Certifications Product Selection Cat. No. Explanation Specifications
Product Overview

Bulletin 1492 Programmable Controller Wiring Systems


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 systems deliver a lower life cycle cost.