PLC Wiring Systems

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PLC Wiring Systems
Interface Cables

• Interface Modules

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1492 Wiring Systems
What is a Wiring System?

• Wiring Systems replace the point-to-point wiring
  between the PLC module I/O terminals and the
  individual terminal blocks in a control panel
• A Wiring System consists of 2 components
• a 1492 wiring system Interface Module which
  replaces terminal blocks
• a pre-wired Interface Cable to connect the PLC
  I/O module to the wiring system Interface module

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1492 In-Panel Wiring Systems General Information
PLC Wiring with 1492 Wiring Systems
Traditional PLC to Terminal Block Wiring
Each PLC I/O Point Individually Routed Landed
At Terminal Block
Pre-Wired 1492 Cables
Begin at PLC End at 1492 Module
DIN Rail
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1492 Wiring Systems
General Wiring System Advantages

• Provide features that reduce installation and
  commissioning time and costs while providing
  flexibility
• Reduce Wiring Time by 60 to 85
• Wire preparation (cut, strip, tag connect) time
  eliminated and wire tray routing time greatly
  reduced
• Assembly of individual Terminal Blocks and
  connection to DIN rail eliminated
• Wiring system modules come with pre-marked
  terminal labels to match the application. Manual
  marking of terminals eliminated
• No Wiring Errors, reduce troubleshooting on
  startup
• All 1492 cables and modules are fully tested
  before shipment
• Modularity
• Ability to match functions (e.g. diagnostic LEDs,
  fusing, etc.) with application
• Result Increased volume and productivity

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1492 Wiring Systems
Why Use Panel Wiring Systems?

• You are an OEM or Panel Builder who needs to
  save panel space
• You are an OEM or Panel Builder who is
  interested in saving installation time
• You have a Project where incentive exists for
  delivery
• You are an OEM or Panel Builder competing
  w/offshore house (lower labor)
• You are a User who has limited I/O wiring
  expertise

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1492 Wiring Systems Compatible Devices

• Packaged PLC Controllers
• MicroLogix 1200 (1762 -40 I/O)
• MicroLogix 1500 (1764)
• Modular PLC Controllers
• SLC500 (1746)
• ControlLogix (1756)
• CompactLogix (1769)
• PLC5 (1771)
• 700 PowerFlex Drives
• 700H Control I/O
• 700S Control I/O

1771
1746
1756
1764
1492 Wiring Systems
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NEW1492 Wiring System Products
Modicon to 1756 Swing-arm Conversion
Objective Simplify customer transition from
Modicon 800 to 1756
MODICON 800 Series
ControlLogix 1756 I/O
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I/O Wiring Conversion System Modicon 800 to
ControlLogix 1756
Modicon to 1756 Transition Options Phased
Migration
Typical Modicon User Installation
Typical First Step Migration Change to Logix
Processor
Final Step Change Series 800 I/O w/1756
Maintain Series 800 I/O Utilize control program
conversion tool
I/O Wiring Conversion system for 800-to-1756
migration
Modicon Series 800 I/O
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Bulletin 1492 I/O Wiring Conversion System
Modicon 800 to ControlLogix 1756
What Makes Up a Bulletin 1492 800-to-1756 I/O
Wiring Conversion System?

• A Wiring Conversion System consists of 6
  components
• the existing 800 I/O swing-arm (terminal block)
  with the attached field wiring
• a Series 800 to 1756 I/O field wire termination
  conversion module
• a 1492 conversion module base mounting plate(1)
• a standard 1492 wiring system cable for the
  compatible 1756 I/O module
• a 1492 I/O rack/chassis conversion mounting
  plate(1)
• a compatible 1756 rack/chassis and
• compatible 1756 I/O modules

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NEW 1492 Wiring System Products Modicon to
1756 Swing-arm Conversion
Value Proposition of Conversion System

• Lowers rewiring labor costs
• 1.5 to 2.0 hours per I/O module without
  conversion system
• 3 to 5 minutes per I/O module with conversion
  system
• Lowers risk of re-wiring mistakes
• Pre-wired cables and modules are factory tested
• Lower engineering layout costs
• Minimizes production downtime

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NEW 1492 Wiring System Products Modicon to
1756 Swing-arm Conversion
Design Goals

• Use the same or less panel space as Modicon when
  possible
• Use the existing Modicon 800 Series swing-arm
  I/O wiring
• No need to drill new holes in panel
• Limit the use of tools to screwdrivers and/or
  wrenches
• Use existing 1492 pre-wired cables for interface
  1756 I/O
• UL, CSA and CE certified

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NEW 1492 Wiring System Products
Modicon to1756 Swing-arm Conversion
Conversion System Components Module
Mounting/Ground Plate
Conversion Module Mounting Ground Plate
800 Series I/O Module Housings

• Matches footprint of original Series 800 I/O
  housing
• Uses same mounting holes hardware as Series
  800 housing
• Ensures good electrical ground connection to
  control panel
• Used to mount conversion modules and 800 I/O
  swing-arms

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NEW 1492 Wiring System Products Modicon to
1756 Swing-arm Conversion
Conversion System Components Module

• Convert 800 Series I/O field wiring to 1756 I/O
  compatible wiring
• Provide fusing if previously available on Series
  800 output
• Provide cable interface connection to 1756 I/O
  module

Cable Interface to 1756 I/O
Slider to open the housing
Lever to open the housing (to change fuse)
Terminals to mate with 800 I/O
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NEW 1492 Wiring System Products Modicon to
1756 Swing-arm Conversion
Conversion System Components Modules (Bottom
View)
Convert 800 Series I/O field wiring to 1756 I/O
compatible wiring
800 I/O Swing-arms
Top
Mounting/Ground Plate
Pre-wired Cable
Bottom
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NEW 1492 Wiring System Products Modicon to
1756 Swing-arm Conversion
Conversion System Components Conversion
Cover/1756 Chassis Mounting Plate
Cover Open

• Protects allows access to conversion modules
• Provides mounting platform for 1756 chassis

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NEW 1492 Wiring System Products Modicon to
1756 Swing-arm Conversion
Conversion System Components Conversion
Cover/1756 Chassis Mounting Plate
Cover Closed
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NEW 1492 Wiring System Products Modicon to
1756 Swing-arm Conversion
Exploded View Conversion System Components
Cover/Mounting Plate
Conversion Module
1756 I/O Interface Cable
800 Series Swing-arm
Mounting/Ground Plate
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1492 Wiring Systems
Get WIRED
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AVAILABLE LITERATURE AND CONFIGURATION TOOLS
Pub 1492-BR016A-EN-P, overview of 1492 wiring
system Pub 1492-TD008D-EN-P, technical data for
1492 wiring system Rockwell Automation Product
Selection Toolbox, DVD for laptop use or on the
RA website. Provides the following configuration
tools for the 1492 wiring system. Proposal
Works Integrated Architecture Builder