FLEX I/O: Flexible Solutions for Distributed Systems

FLEX I/O System

THE BENEFITS OF STANDARDIZING ON FLEX I/O ARE CLEAR: A product that meets global standards and offers you the benefits necessary to minimize your automation life cycle costs. FLEX I/O is a true global product offering: Tailored system design capability Flexibility in control, communication, I/O and termination Lowest installation and maintenance costs Lowest Life Cycle cost Global availability, delivery, support and service World-class quality

FLEX I/O ALLOWS YOU TO STANDARDIZE ON A PLATFORM OF CHOICES IN CONTROL, COMMUNICATION, I/0, AND TERMINATION.

WHAT IS FLEX I/O AND HOW DOES IT WORK?

FLEX I/O is a modular I/O system for I/O applications. The design of FLEX I/O and its components provide all the functionality of larger, rack-based I/O, but saves you the costly hardware, installation, and space requirements of larger systems. What really makes FLEX I/O the I/O product line to standardize on is how the unique design can save and reduce the costs associated with your I/O application. FLEX I/O consists of three interchangeable, space-saving components: Network adapters Terminal base units I/O modules All three FLEX I/O components are compact and interchangeable, allowing you to design and create an I/O system tailored to your specific application requirements. FLEX I/O requires only one adapter for as many as eight terminal bases. When you need more I/O or use a combination of different I/O types, you can meet system requirements without buying additional power supplies and communication adapters.

THE TERMINAL BASE

Your terminal base attaches to the adapter via a bus connector, and through this connector, forms the I/O bus. The terminal base contains a terminal system that allows you to wire your sensors and actuators directly, eliminating the need for terminal blocks, and the additional wiring, labor and installation costs associated with them! Terminal bases are available for two, three, and four-wire devices and are available in several popular styles.

The choices and flexibility you have with I/O types range from digital and analog to temperature and motion control. FLEX I/O allows you to use as many as eight terminal bases per adapter that provides a maximum of 128 digital I/O or 64 analog input or 32 analog output channels per adapter. You can mix and match digital and analog I/O with mounting and wiring options, supplying you with a successful distributed system solution!

THE I/O MODULE

The I/O module plugs in to the terminal base, connecting to the I/O bus and field devices. Because there is no direct wiring to the I/O module, you can remove and insert modules under power, enabling you to change modules without disturbing field wiring, other I/O modules, or system power. This eliminates costly downtime and the inefficiencies of restarting a system.

THE NETWORK ADAPTER

Depending on your network type, you can choose from one of Rockwell Automations network architectures: RIO, DeviceNet , ControlNet . Contact your local Rockwell Automation office for other network connections.

Standardizing on FLEX I/O means you no longer have to rely on multiple vendors for multiple I/O system components. FLEX I/O is your single source that provides you with the flexibility, cost savings and choices you need for your distributed I/O system solutions.

FLEX I/O eliminated my marshalling cabinet and brought my control closer to my application. This reduced my terminations by 50% and all the wiring, labor, panel space and time associated with it."

FOUR REASONS YOU SHOULD STANDARDIZE ON FLEX I/O:

1. REDUCE INSTALLATION COSTS

When you install, expand or upgrade your system, you want to reduce and where possible, eliminate the associated expenses. When you install a new system, you want to keep your space requirements to a minimum and when you expand or upgrade, you want to maintain, or even reduce your space requirements. FLEX I/Os combination of a terminal strip and an I/O interface eliminates the need for terminal blocks, placing the I/O close to the field device and resulting in reduced wiring costs. Since there are no terminal blocks, you no longer need to wire between your I/O modules and the terminal block. Eliminating the terminal blocks reduces your number of required terminations, meaning you save the costs of: Terminal blocks and the wiring and hardware associated with them Hard-wired cable trays and heavy duty conduit The marshalling cabinet in your control room Engineering, labor, and maintenance that extra wiring and terminations require Control panel hardware and space

The benefits of this feature are realized should system problems develop. You avoid time-consuming maintenance procedures and the costs of system interruptions when maintenance or troubleshooting problems arise. Removing and inserting modules under power means you save the costs of: System downtime Maintenance and troubleshooting System restarts Terminal bases also contain a module keying mechanism designed to prevent module replacement errors.

Standardizing on a complete and comprehensive FLEX I/O package saves you the time and costs of: Engineering your system drawings Tracking and managing various vendors specifications and system requirements Maintaining and troubleshooting your system Multiple hardware components

4. REDUCE STARTUP COSTS AND SAVE TIME

Low installation, wiring, and maintenance costs are the result of FLEX I/Os combined terminal strip and I/O interface. This saves you time and cost of starting up your system. The modular system can be pre-built, tested, and easily reconnected at the customers facility. In a traditional wiring installation, you have up to 12 terminations per I/O device from the field to the I/O module. By mounting FLEX I/O in the field-mounted junction box, the number of terminations is reduced from 12 to 4 terminations per field device. The reduction in termination points with FLEX I/O provides two major benefits: Reduces the possibility of miswiring Improves your checkout and commissioning time

3. REDUCE SYSTEM DESIGN COSTS

FLEX I/O offers you the flexibility of "off the shelf I/O. The variety of choices in control, communication, I/O and terminations allows you to use one I/O system for all your application needs: Digital Analog Temperature Relay Counters Multiple choices saves the time, energy and resources it takes to manage a distributed system containing equipment from multiple vendors. FLEX I/O provides you with a combination of modules to choose from to match your application allowing you to reduce space and cost of your complete system solution.

2. ELIMINATE SYSTEM DOWNTIME TO REPLACE MODULES

FLEX I/O modules contain no wiring and are easily removed and inserted under power (RIUP) without disturbing field device wiring, other I/O modules, or system power!

VAX System

Windows NT or Windows 95

Information / Data Level

"Our problem was managing and tracking specs and requirements of the various manufacturers associated with our installation. FLEX I/O gives us a standardized package with the simplicity, flexibility and choices we need."

PLC-5 Controller

RSLogix 5 RSLinx FLEX I/O Control Level

PLC-5 Controller

FLEX I/O

SLC 500

FLEX I/O

Discrete Device Level

Process Device Level

Photoelectric Sensor FLEX I/O Limit Switch

Flow Meter Transducer Temperature Monitor Valves

FLEX I/O

Smart Speed Controller

FLEX I/O: CHOICES IN I/O, CONTROL, COMMUNICATION, AND TERMINATION

CHOOSE THE CONTROLLER YOU NEED WITHOUT SWITCHING YOUR I/O.

The benefits of standardizing on a global product like FLEX I/O are further realized at the control level. The design of FLEX I/O makes the system independent of the control platform. This means you can choose the type of control you need to meet your application requirements. And, if your application requirements change, your I/O can stay the same! This means you can tailor FLEX I/O to fit your current application and not worry about changing in the future. This design protects your current investment and helps you avoid costs of changing your control platform should the need ever arise. With FLEX I/O, your control choices are: PC Control Proprietary Controllers PLC - programmable logic controller SLC - small logic controller DCS - distributed control systems Motion Controller Because FLEX I/O is a global product, it allows you to work with control platforms from many global vendors. In addition, FLEX I/O is an ideal platform for data acquisition applications, whether its data logging for traceability, or SCADA in a fully distributed architecture.

PROTECT YOUR INSTALLED BASE BY SIMPLY CHOOSING THE COMMUNICATION ADAPTER YOU NEED.
Standardizing on FLEX I/O means you can connect to your existing installed base communication protocol. Simply choose the FLEX I/O communication adapter to meet your network communication requirements and make your network connection: Allen-Bradley Remote I/O DeviceNet ControlNet Other networks from partner companies The versatile design of the communication adapter lets you change your communication without changing or replacing your installed I/O. Choose the particular communication adapter to match your control platform and install it into your existing FLEX I/O installation. You will be instantly connected to all the control devices that communicate on your network! This variety of core network communications protects your current and future investment by allowing you the versatility you expect from a flexible and standardized platform.

MIX OR MATCH MULTIPLE I/O TO MULTIPLE DEVICES

The FLEX I/O system is ideal for distributed applications because it lets you mix or match the I/O modules you need with your choices in sensors and actuators. This flexibility gives you the choices of I/O signal types: Digital: AC and DC voltage signals Analog: current or voltage and low level Relay: normally open, 2 amp capability Protected outputs: non-latching, latching, and diagnostics Temperature: thermocouple or RTD Motion: high speed counters, flow metering, and totalization Intrinsic Safety: a complete selection of hazardous area field device interfaces Combo modules: combination of input and output capability FLEX I/O combo modules allow you to match I/O to field devices for smaller system requirements saving space and installation costs. Partitioning I/O allows maximization of system integrity while minimizing cost per point of input and output modules. These choices allow you to design a system that is easily expandable as your I/O system needs and the FLEX I/O product line grows.

Space-saving design and choices in mounting and panel design add to the growing list of reasons why FLEX I/O is the product line to standardize on! "The reduction in terminations helped simplify and speed up system checkout and start up. This got my system up and running in a fraction of what it used to take."

FLEX I/O'S SPACE-SAVING DESIGN MEANS MOUNTING CHOICES AND MORE REASONS TO STANDARDIZE.

When it comes to installing your I/O, you need mounting flexibility to work within your limited space requirements.

HOW ARE YOU REWARDED WITH FLEX CHOICES?

Mounting choices and flexibility makes FLEX I/O: Scaleable: mount from one to eight modules per node with a maximum of 128 digital I/O, 64 analog input, or 32 analog output channels per adapter. Modular: mount your I/O vertically or horizontally in continuous stacks or segments. Use the optional extender cables in 0.3m or 0.9m lengths to arrange your system in rows or split your system into horizontal and vertical orientations. Flexible: mount directly on a standard DIN rail or use the optional mounting kit to mount to a wall or panel. Compact: FLEX I/O's space-saving dimensions make it easy for you to fit into smaller, less expensive control panels. System Partitioning: combination I/O modules, dual module adapters, and low density integrated I/O modules allows partitioning of your system around particular applications, thus improving overall system availability and/or minimizing unused I/O channels.

SAVE SPACE NOW AND IN THE FUTURE

FLEX I/0's space-saving design combines the terminations and I/O into one compact and modular unit. This not only saves you the expenses of related hardware and labor, but also costly control cabinet and panel space! When you need to add more I/O or use a combination of different I/O types, you can meet your application needs without adding additional power supplies and communication adapters (nodes).

CHOICES IN MOUNTING DESIGNS

Whether you mount your I/O in large central concentrations or small highlydistributed panels, FLEX I/O allows you to use several different mounting designs. If you are upgrading, FLEX I/O can fit easily into your existing control space, or into smaller, less-expensive control spaces, such as junction boxes, in a new installation. This increases your productivity and decreases your costly space requirements!

These choices provide you with the versatility you need to connect your various two, three, and four-wire sensors and actuators. Choose from terminal bases that give you the flexibility you need to handle your wiring and application needs: NEMA Screw: 2-tier version accept standard and heavy gauge wiring Spring clamp: 3-tier version provides faster and simpler wiring installation Screw clamp: 3-tier version standard terminal strip style Fused: for circuit protection applications Temperature: provides connection for cold junction compensation Grounded: provides ground connection on the terminal base

BRING YOUR CONTROL CLOSER TO YOUR APPLICATION

The FLEX I/O system is ideal for distributed applications because its unique design essentially eliminates the marshalling cabinet. You connect your sensors and actuators directly to the FLEX I/O terminal base that contains the I/O module. This not only reduces your number of terminations, but also lets you bring your control closer to or directly on your application's machine for wiring and termination reduction.

THE REWARDS OF TERMINATION CHOICES MEANS SMART TERMINATION DESIGNS

An added benefit of FLEX I/O's choices in termination styles provides smart termination design.

HOW TO TAKE THE NEXT STEP TOWARDS STANDARDIZING ON FLEX I/O: Contact your local Rockwell Automation sales office, distributor or system integrator and tell them that you want to standardize on FLEX I/O, the I/O of choices for your distributed system solutions.

MAXIMIZE YOUR AUTOMATION LIFE CYCLE INVESTMENT BY LOWERING YOUR LIFE CYCLE COSTS.

The Automation Investment Life Cycle includes enhancing productivity, lowering total costs, and providing continuous improvement. Studies have shown that more money is often spent in the last three phases of the life cycle model than in the first three, yet project decisions are often made on only purchase cost criteria. FLEX I/O is designed to reduce the total cost of your investment. Now, more than ever, the reasons to standardize on a global product are obvious, especially at each phase of the Automation Investment Life Cycle. FLEX I/O is the I/O of choices for your distributed system solution. FLEX I/O enables you to: Justify: FLEX I/O's space and hardware-saving design reduces: - installation costs - system downtime and related costs - system design costs - startup costs and time Apply: The FLEX I/O system offers you choices in: - control - communication - I/O - termination These choices allow you to design a system tailored to your application needs. A tailored system lets you apply the best cost-effective solutions to your distributed applications. Install: Your installation costs are lower because FLEX I/O reduces your: - terminations and expenses of wiring - control panel hardware and space - time and labor - engineering and system design

Operate: FLEX I/O simplifies your application and enhances your system operation by reducing: - system downtime and costs - system design costs - system startup costs Maintain: Simplifying and reducing your terminations and hardware: - saves time and money - provides easier system maintenance FLEX I/O's versatility and variety of choices protects your current investment by allowing you to expand your system without re-engineering your current installation. Improve: Allen-Bradley is committed to the future development of FLEX I/O, meaning your choices will grow as your application needs and the FLEX I/O product line grows.

Expansion of our line of communication platforms and termination styles A new line of low-cost integrated FLEX I/O that will meet the needs of value conscious customers This commitment to the future means that as your system requirements change, FLEX I/O will be there to meet those requirements by offering you more choices in control, communication, I/O and termination.

STANDARDIZE ON GLOBAL QUALITY, SUPPORT AND SERVICE

When you standardize on FLEX I/O, you are guaranteed the quality, support and service Allen-Bradley has been delivering to the global marketplace for over 90 years: Global distribution system readily available with fully-stocked inventories of spare parts World-wide training and support centers prepared to offer around-the-clock assistance History of quality unmatched in the industrial automation industry We offer a network of sales offices, distributors and system integrators that can provide you with a quick and capable response to your needs, anywhere in the world.
Copyright 1997 Rockwell International All trademarks and registered trademarks are property of their respective companies.

WHY OUR COMMITMENT TO THE FUTURE IS IMPORTANT TO YOU

When you standardize on a product line, you are making a commitment to the future. You expect the product line manufacturer to do the same. Our FLEX I/O engineering and development teams are concentrating on your needs for tomorrow's industrial automation needs. We are working hard at developing and delivering more choices for your future distributed I/O applications: A full line of intrinsically safe FLEX I/O adapters, modules, and terminal bases for hazardous area applications

Allen-Bradley, a Rockwell automation business, has been helping its customers improve productivity and quality for more than 90 years. We design, manufacture and support a broad range of automation products worldwide. They include logic processors, power and motion control devices, operator interfaces, sensors and a variety of software. Rockwell is one of the worlds leading technology companies.

Worldwide representation.
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Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 1794-1.16 - September 1997

Copyright 1997 Rockwell International Corporation Printed in USA