Modicon 800 to ControlLogix Bulletin 1756 I/O Field Wiring Conversion System. Selection Guide

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1 Modicon 800 to ControlLogix Bulletin 1756 I/O Field Wiring Conversion System Selection Guide

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3 Table of Contents Bulletin 1492 Modicon 800 to ControlLogix 1756 I/O Field Wire Conversion System The Bulletin 1492 Modicon 800 to ControlLogix 1756 I/O field wire conversion system provides a fast and efficient way to convert the existing I/O field wires from a Modicon 800 I/O system to a ControlLogix 1756 I/O system. The Bulletin 1492 conversion system enables the field wiring on a particular 800 I/O module terminal block (swing-arm) to be maintained, so there is no or very limited rewiring required to convert to a compatible 1756 I/O module. Conversion solutions are available for 20 of the most widely used Modicon I/O modules. Time Saving Features this page Conversion Modules and Cables 4 Conversion of the 800 I/O Housing 5 Conversion of the 800 I/O Modules 6 Typical Keys to Conversion Success: 800-to- Bulletin 1756 Field Wire Conversion System 7 Conversion Module Specifications 7 Conversion Module Installation and Application Considerations 8 Time Saving Features The time to convert for example the field wiring for a Modicon 8-slot I/O housing/rack without the conversion system can typically be between seven to nine hours. This assumes time to: Unscrew and remove each I/O wire from each I/O module terminal block Remove the old I/O housing/rack from the control cabinet Drill new holes in the control cabinet for the new I/O rack Mount the new I/O rack Install the new I/O modules in the new I/O rack Re-dress each I/O wire for each module Re-label each I/O wire Attach each wire to the I/O module terminal block Confirm operation: Once the conversion of field wires is complete the integrity of each connection has to be verified to ensure a wiring error wasn't made. This troubleshooting process may add 30 minutes or several hours to the conversion. The conversion system potentially reduces the 7 to 10 hours required to convert the field wiring for an 8-slot I/O housing/rack to one hour or less. In many applications, saving 6 to 8 hours of downtime can eliminate tens to hundreds of thousands of dollars of revenue. Multiply that savings by the number of 8-slot housings in your factory and you can see the benefit of the I/O conversion system. Estimate using all 16 pt. I/O modules and typical assembly times. Time with conversion system approximately one hour. 3

4 Product Overview 1492 Conversion System BASICS Conversion Modules and Cables The Bulletin 1492 conversion system virtually eliminates the rewiring process by using conversion modules. The conversion modules provide the mating connections to the specific Modicon 800 I/O terminal block with the attached field wires. It routes those field signals, via a standard 1492 wiring system connector and a 1492 pre-wired cable to the compatible terminals of the 1756 I/O module. Conversion Modules Pre-wired 1492 Cables Conversion Assembly Base-Plate Conversion Assembly Cover-Plate The conversion modules are housed in a conversion assembly base-plate which uses the same mounting footprint and panel mounting holes as the Modicon 800 I/O Housing it replaces. Therefore, no new holes need be drilled in the control cabinet. The conversion assembly cover-plate covers and protects the conversion modules, while providing the mounting platform for the Bulletin 1756 I/O chassis and associated I/O modules. NOTE: The total depth of the conversion assembly and mounted Bulletin 1756 chassis is less than the original Modicon I/O housing. 4

5 Conversion of the 800 I/O Housing Product Overview The following table provides selection information for the conversion assembly base-plate and cover-plate. The selection process is based on the previously installed Modicon 800 I/O housing. These components function as a matched set and therefore ship as a single catalog number. Conversion Systems Components - Exploded View 800 Housing to 1756 Chassis Conversion System Selection Process Step 1: Determine the catalog type and number of 800 I/O modules used in the the 800 I/O Housing to be converted to Bulletin 1756 I/O. Step 2: Refer to column 1 Find the Modicon 800 I/O Housing catalog number Step 3: Refer to column 5 Review and select a Bulletin 1756 I/O Chassis catalog number from column 4 which meets your conversion needs. Note: Ensure the information from the I/O Conversion module (tables two and three) is reviewed first since in some cases, two 1756 modules are needed to replace one 800 I/O module. Step 4: Refer to column 7 Select the Conversion Assembly catalog number. Table 1: 800 Housing to Bulletin 1756 Chassis Conversion Modicon 800 I/O Housing Catalog Number Max Number of 800 Housing Slots for I/O 800 Housing Width Dimension Bulletin 1756 I/O Chassis Catalog Number Max Number of Bulletin 1756 Chassis Slots for I/O Bulletin 1756 Chassis Width Dimension Conversion Assembly Catalog Number AS-H810-xxx " 1756-A " 1492-MUA4-MB3 AS-H " A7=6, A10=9 AS-H " 1756-A7 or 1756-A10 A7=6, A10=9 A7=14.49" 1492-MUA7-A10- A10=19.02" MB4679 AS-H " A7=6, A10=9 AS-H " A10=9, A13= A10 or AS-H " A10=9, A13=12 A10=19.02" 1492-MUA10-A13- A13 A13=23.15" MB " AS-H A10=9, A13=12 One chassis slot required for the ControlLogix processor or a remote I/O adapter type module The footprint and mounting dimensions of the Bulletin 1492 Conversion Assembly (base-plate and cover-plate) match those of the Modicon I/O Housing Width dimension includes the Bulletin 1756 Chassis power supply Surplus Chassis width as compared to the 800 I/O Housing divided equally when mounting it on the Conversion Assembly Cover Plate Mounting holes for the Bulletin 1756 I/O Chassis are pre-drilled and tapped in the Conversion Assembly Coverplate 5

6 Product Selection Conversion of the 800 I/O Modules Tables 2 and 3 provide selection information for the Bulletin 1492 Modicon 800 to 1756 I/O conversion system modules. Use the following steps to select the proper module. Step 1: Refer to column 1 Find the catalog number of the 800 Series I/O modules you are currently using. Step 2: Columns 2, 3, and 4 list the catalog numbers of the compatible Bulletin 1756 I/O module, Bulletin 1492 Conversion module, and Bulletin 1492 cable to connect the conversion module to the Bulletin 1756 I/O module. Step 3: Review and understand the Bulletin 1756-to-800 module Application Considerations, starting on page 8. relieved Table 2: Conversion of the I/O Modules - Digital Modicon 800 Digital I/O Module Catalog Number Control Logix Bulletin 1756 Digital I/O Replacement Module Bulletin 1492 I/O Conversion Module Catalog Number Conv. Module to Bulletin 1756 Module Cable Catalog Number AS-B OA CM800-LD CABLE003U AS-B OA CM800-LD CABLE003X AS-B OB16E 1492-CM800-LD CABLE003X AS-B IA CM800-LD CABLE003X AS-B IA CM800-LD CABLE003X AS-B OA CM800-LD CABLE003X AS-B IA CM800-LD CABLE003Z AS-B OB CM800-LD CABLE003U AS-B OC CM800-LD CABLE003U AS-B IB CM800-LD CABLE003X AS-B IC CM800-LD CABLE003X AS-B IB CM800-LD CABLE003X AS-B OB CM800-LD CABLE003Z AS-B IB CM800-LD CABLE003Z AS-B OB CM800-LD CABLE003Z AS-B OB16E 1492-CM800-LD CABLE003X AS-B OA8E 1492-CM800-LD CABLE003U AS-B OA16I 1492-CM800-LD CABLE003Y AS-B OX8I 1492-CM800-LD CABLE003Y AS-B OX8I 1492-CM800-LD CABLE003Y Table 3 - Conversion of the I/O Modules - Analog Modicon 800 Analog I/O Module Catalog Number Control Logix Bulletin 1756 Analog I/O Replacement Module Bulletin 1492 I/O Conversion Module Catalog Number Conv. Module to Bulletin 1756 Module Cable Catalog Number AS-B IF16 (Differential Current) 1492-CM800-LA ACABLE003UD AS-B IF16 (Differential Voltage) 1492-CM800-LA ACABLE003UC AS-B IF16 (Single-ended Current) 1492-CM800-LA ACABLE003UB AS-B IF16 (Single-ended Voltage) 1492-CM800-LA ACABLE003UA AS-B OF6CI 1492-CM800-LA ACABLE003Y AS-B OF6VI 1492-CM800-LA ACABLE003Y Recommended cable length of 0.3M is shown. Other cables lengths in increments of 0.1M are available, please see Industrial Controls Catalog for more information. Conversion module is fused to match Modicon output module functionality Two Bulletin 1756 modules and two Bulletin 1492 cables are required to match Modicon functionality 6

7 Typical Keys to Conversion Success: 800-to-1756 Field Wire Conversion System Specifications Up front conversion planning and adequate conversion time budgeting are the key elements to field wire conversion success. The following are several points specific to these elements. There may be other points unique to your application or installation. Typical keys to field wire conversion success are: Study and use Tables 1-3, select the correct 1492 conversion assemblies, modules and cables specific to your Modicon 800 I/O system. If a 1492 conversion module is not listed in the table on page 5, the 1756 I/O module needs to be manually converted/re-wired. Study and use the wiring diagrams specific to the Modicon 800-to-1756 conversion modules being used. Pay particular attention to the Conversion Module Installation and Application Considerations that apply for each 1492 conversion module, especially items such as the PLC output module current load switching differences. In addition, compare the Modicon and 1756 I/O module specifications from the respective commercial, installation and/or user documents to ensure any implication of the differences are understood and appropriate system modifications are performed as part of the conversion. Order the 1492 conversion components assembly, module, and cables, well in advance (8-12 weeks) of the shutdown scheduled to perform the conversion. When the 1492 conversion components arrive, inventory and physically inspect them to ensure nothing was damaged during shipment. Note: It is recommended that several spares of each 1492 conversion module and cable be ordered to ensure a damaged component doesn't impact the scheduled date of the conversion due to possible shipment delay of the replacement component. The number of 1492 module X spares to order depends on how many of conversion module X is used in the conversion. Inspect the existing Modicon 800 I/O module terminal blocks for any possible physical or electrical damage, prior to conversion. Damaged terminal blocks should be replaced during the conversion to ensure reliable mechanical and electrical connection to the 1492 conversion modules. Fully review and understand the conversion system Installation Instruction manual. If possible, have assigned conversion personnel practice using the 1492 conversion hardware, so component assembly confusion is limited during the actual conversion. Conversion Module Specifications Dimensions (H x D x W) Approximate Shipping Weight Storage Temperature Operating Temperature Operating Humidity Shock Operational Vibration Maximum Operating Voltage Maximum Module Operating Current Fusing: Agency Certifications CE Certifications Specification Non-operating Operating A/C I/O: D/C I/O: Analog I/O: Per Point Per Module 1492-CM800-LD CM800-LD CM800-LD CM800-LD CM800-LD CM800-LD015 Value x x 44.5 mm (11.37 x 5.5 x 1.75 in.) 300g (0.66 lb) C ( F) C ( F) % at +55 C (+131 F) 50 g 30 g 2 g at Hz 125V AC at Hz 150V DC 60V DC 2 A 12 A Two, 4A 5x20 mm Two, 4A 5x20 mm Two, 4A 5x20 mm Two, 4A 5x20 mm Eight, 1A 5x20 mm Eight, 2A 5x20 mm UL Classified (UL File No. E113724) CSA Compliant for all applicable directives Pollution Degree 2 Environmental Rating Operating specifications are when installed in the conversion system base and cover plate assembly CABLE connection pins are limited to 2 A per pin. Note: Refer to the wiring diagrams for current limits for a specific configuration. IP20 7

8 Converting to ControlLogix 1756 I/O - Application Considerations From a functional and product features perspective; ControlLogix and Bulletin 1756 I/O are far superior to the Modicon 800 I/O. However, there are some Bulletin 1756 I/O product differences such as in some cases lower output module current switching capability that need to be considered in your application before converting I/O platforms. The following drawings provide many of these key Application Considerations, along with the wiring or though diagram from the Modicon 800 I/O module terminal block, conversion module, pre-wired cable and up to the terminal block of the compatible Bulletin 1756 I/O module. This information must be well understood before the actual conversion. In addition, the specification section of the Modicon 800 and ControlLogix Bulletin 1756 I/O module installation and user manual should be compared to ensure there are no other considerations that critically impact your application. Conversion Module Installation and Application Considerations 8

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35 Approximate Dimensions Preferred Availibility cat. nos. are printed in bold 35

36 Approximate Dimensions 36 Preferred Availibility cat. nos. are printed in bold

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38 Allen-Bradley, Rockwell Software, and ControlLogix are trademarks of Rockwell Automation, Inc. Publication 1492-SG120B-EN-P August 2009 Copyright 2009 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.