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. delivery. support and service •World-class quality . I/O and termination • Lowest installation and maintenance costs • Lowest Life Cycle cost • Global availability. FLEX I/O is a true global product offering: •Tailored system design capability • Flexibility in control. communication.

ControlNet™ . . The terminal base contains a terminal system that allows you to wire your sensors and actuators directly. enabling you to change modules without disturbing field wiring. WHAT IS FLEX I/O AND HOW DOES IT WORK? FLEX I/O is a modular I/O system for I/O applications. THE NETWORK ADAPTER Depending on your network type. Because there is no direct wiring to the I/O module. Contact your local Rockwell Automation office for other network connections. but saves you the costly hardware. and space requirements of larger systems. When you need more I/O or use a combination of different I/O types. other I/O modules. or system power. 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. 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. You can mix and match digital and analog I/O with mounting and wiring options. FLEX I/O consists of three interchangeable. cost savings and choices you need for your distributed I/O system solutions. and four-wire devices and are available in several popular styles. and the additional wiring. labor and installation costs associated with them! Terminal bases are available for two. eliminating the need for terminal blocks. ™ THE TERMINAL BASE Your terminal base attaches to the adapter via a bus connector. 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 STANDARDIZE ON A PLATFORM OF CHOICES IN CONTROL. The design of FLEX I/O and its components provide all the functionality of larger. three. you can meet system requirements without buying additional power supplies and communication adapters. I/0. forms the I/O bus. installation. supplying you with a successful distributed system solution! THE I/O MODULE The I/O module plugs in to the terminal base. This eliminates costly downtime and the inefficiencies of restarting a system. AND TERMINATION. you can remove and insert modules under power. rack-based I/O. FLEX I/O requires only one adapter for as many as eight terminal bases. allowing you to design and create an I/O system tailored to your specific application requirements. space-saving components: • Network adapters • Terminal base units • I/O modules All three FLEX I/O components are compact and interchangeable. you can choose from one of Rockwell Automation’s network architectures: RIO. connecting to the I/O bus and field devices. 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. DeviceNet™ . COMMUNICATION. and through this connector.

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

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. and easily reconnected at the customer’s facility. eliminate the associated expenses. you want to keep your space requirements to a minimum and when you expand or upgrade. By mounting FLEX I/O in the field-mounted junction box. This saves you time and cost of starting up your system. or system power! . In a traditional wiring installation. energy and resources it takes to manage a distributed system containing equipment from multiple vendors. 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. 2. 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. you want to maintain. tested. you have up to 12 terminations per I/O device from the field to the I/O module. you no longer need to wire between your I/O modules and the terminal block.FOUR REASONS YOU SHOULD STANDARDIZE ON FLEX I/O: 1. The modular system can be pre-built. labor. REDUCE STARTUP COSTS AND SAVE TIME Low installation.” The variety of choices in control. 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. other I/O modules. REDUCE SYSTEM DESIGN COSTS FLEX I/O offers you the flexibility of "off the shelf I/O. You avoid time-consuming maintenance procedures and the costs of system interruptions when maintenance or troubleshooting problems arise. When you install a new system. 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. placing the I/O close to the field device and resulting in reduced wiring costs. or even reduce your space requirements. Eliminating the terminal blocks reduces your number of required terminations. communication. 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. and maintenance that extra wiring and terminations require • Control panel hardware and space The benefits of this feature are realized should system problems develop. the number of terminations is reduced from 12 to 4 terminations per field device. you want to reduce and where possible. expand or upgrade your system. wiring. Since there are no terminal blocks. FLEX I/O’s combination of a terminal strip and an I/O interface eliminates the need for terminal blocks. and maintenance costs are the result of FLEX I/O’s combined terminal strip and I/O interface. REDUCE INSTALLATION COSTS When you install.

FLEX I/O gives us a standardized package with the simplicity.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. 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 .

The benefits of standardizing on a global product like FLEX I/O are further realized at the control level. 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. This means you can choose the type of control you need to meet your application requirements.programmable logic controller • SLC . 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.small logic controller • DCS . if your application requirements change. PROTECT YOUR INSTALLED BASE BY SIMPLY CHOOSING THE COMMUNICATION ADAPTER YOU NEED.FLEX I/O: CHOICES IN I/O. CONTROL. and diagnostics • Temperature: thermocouple or RTD • Motion: high speed counters. COMMUNICATION. your control choices are: • PC Control • Proprietary Controllers • PLC . Standardizing on FLEX I/O means you can connect to your existing installed base communication protocol. And. 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. 2 amp capability • Protected outputs: non-latching.distributed control systems • Motion Controller Because FLEX I/O is a global product. AND TERMINATION CHOOSE THE CONTROLLER YOU NEED WITHOUT SWITCHING YOUR I/O. . whether it’s data logging for traceability. 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. or SCADA in a fully distributed architecture. In addition. 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. Choose the particular communication adapter to match your control platform and install it into your existing FLEX I/O installation. The design of FLEX I/O makes the system independent of the control platform. Partitioning I/O allows maximization of system integrity while minimizing cost per point of input and output modules. it allows you to work with control platforms from many global vendors. With FLEX I/O. latching. This design protects your current investment and helps you avoid costs of changing your control platform should the need ever arise. FLEX I/O is an ideal platform for data acquisition applications. 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. 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.

" .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.

but also lets you bring your control closer to or directly on your application's machine for wiring and termination reduction. You connect your sensors and actuators directly to the FLEX I/O terminal base that contains the I/O module.FLEX I/O'S SPACE-SAVING DESIGN MEANS MOUNTING CHOICES AND MORE REASONS TO STANDARDIZE. dual module adapters. FLEX I/O allows you to use several different mounting designs. or 32 analog output channels per adapter. and low density integrated I/O modules allows partitioning of your system around particular applications. in a new installation. or into smaller. less expensive control panels. 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. CHOICES IN MOUNTING DESIGNS Whether you mount your I/O in large central concentrations or small highlydistributed panels. • Modular: mount your I/O vertically or horizontally in continuous stacks or segments. If you are upgrading. 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. 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. three. such as junction boxes. This increases your productivity and decreases your costly space requirements! These choices provide you with the versatility you need to connect your various two. When it comes to installing your I/O.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. FLEX I/O can fit easily into your existing control space. and four-wire sensors and actuators. • System Partitioning: combination I/O modules. 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. Use the optional extender cables in 0. 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. This not only reduces your number of terminations. you need mounting flexibility to work within your limited space requirements. This not only saves you the expenses of related hardware and labor. thus improving overall system availability and/or minimizing unused I/O channels. less-expensive control spaces. . you can meet your application needs without adding additional power supplies and communication adapters (nodes).3m or 0.

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

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. yet project decisions are often made on only purchase cost criteria. FLEX I/O is designed to reduce the total cost of your investment. and terminal bases for hazardous area applications . meaning your choices will grow as your application needs and the FLEX I/O product line grows.installation costs .engineering and system design • Operate: FLEX I/O simplifies your application and enhances your system operation by reducing: . 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. SUPPORT AND SERVICE When you standardize on FLEX I/O. • Improve: Allen-Bradley is committed to the future development of FLEX I/O. WHY OUR COMMITMENT TO THE FUTURE IS IMPORTANT TO YOU When you standardize on a product line. lowering total costs. STANDARDIZE ON GLOBAL QUALITY. anywhere in the world.I/O . FLEX I/O enables you to: • Justify: FLEX I/O's space and hardware-saving design reduces: . You expect the product line manufacturer to do the same. and providing continuous improvement.system startup costs • Maintain: Simplifying and reducing your terminations and hardware: . • 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.communication .control panel hardware and space .MAXIMIZE YOUR AUTOMATION LIFE CYCLE INVESTMENT BY LOWERING YOUR LIFE CYCLE COSTS. FLEX I/O is the I/O of choices for your distributed system solution.system design costs .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. you are guaranteed the quality. modules.time and labor . more than ever.system downtime and costs . you are making a commitment to the future. FLEX I/O will be there to meet those requirements by offering you more choices in control.control . I/O and termination. A tailored system lets you apply the best cost-effective solutions to your distributed applications.system downtime and related costs .saves time and money . Our FLEX I/O engineering and development teams are concentrating on your needs for tomorrow's industrial automation needs. • Install: Your installation costs are lower because FLEX I/O reduces your: . The Automation Investment Life Cycle™ includes enhancing productivity. distributors and system integrators that can provide you with a quick and capable response to your needs.system design costs . especially at each phase of the Automation Investment Life Cycle. the reasons to standardize on a global product are obvious. Studies have shown that more money is often spent in the last three phases of the life cycle model than in the first three. Copyright 1997 Rockwell International All trademarks and registered trademarks are property of their respective companies.terminations and expenses of wiring . Now.startup costs and time • Apply: The FLEX I/O system offers you choices in: .termination These choices allow you to design a system tailored to your application needs. communication.

1201 South Second Street. Worldwide representation. Rockwell is one of the world’s leading technology companies. a Rockwell automation business. PRC • Colombia • Costa Rica • Croatia • Cyprus • Czech Republic • Denmark Ecuador • Egypt • El Salvador • Finland • France • Germany • Greece • Guatemala • Honduras • Hong Kong • Hungary • Iceland • India • Indonesia • Ireland • Israel • Italy Jamaica • Japan • Jordan • Korea • Kuwait • Lebanon • Malaysia • Mexico • Netherlands • New Zealand • Norway • Pakistan • Peru • Philippines • Poland • Portugal Puerto Rico • Qatar • Romania • Russia–CIS • Saudi Arabia • Singapore • Slovakia • Slovenia • South Africa. sensors and a variety of software. has been helping its customers improve productivity and quality for more than 90 years.September 1997 Copyright 1997 Rockwell International Corporation Printed in USA . Republic • Spain • Sweden • Switzerland • Taiwan • Thailand Turkey • United Arab Emirates • United Kingdom • United States • Uruguay • Venezuela • Yugoslavia Allen-Bradley Headquarters. WI 53204 USA. We design. Argentina • Australia • Austria • Bahrain • Belgium • Brazil • Bulgaria • Canada • Chile • China. Tel: (1) 414 382-2000 Fax: (1) 414 382-4444 Publication 1794-1.Allen-Bradley. Milwaukee.16 . They include logic processors. operator interfaces. manufacture and support a broad range of automation products worldwide. power and motion control devices.

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