system cabling for controllers - dam-mdc.phoenixcontact.com · phoenix contact 3 contents...
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System cabling for controllersEffi cient wiring
2 PHOENIX CONTACT
Reducing wiring eff ortToday, machines and systems are becoming more and more complex. As a result, the
wiring eff ort of individual components in an automation system is becoming more
extensive. Planning, assembly, and startup often take a large amount of time. Wiring
errors and tedious troubleshooting cannot be ruled out. With the product portfolio
from Phoenix Contact, these diffi culties are a thing of the past.
Wiring with single wires
Connecting 80 or more individual terminal
points per I/O module is time-consuming,
error-prone, and results in confusing cable
bundles.
Wiring with system cables is
90% faster
Wiring with VARIOFACE system cabling is
at least 90% faster than with single wires.
PHOENIX CONTACT 3
Contents
Controller-specifi c system cabling
The wiring concept 4
PLC-V8 adapters 6
Signal and power wiring 8
Potential distributors and universal
modules 10
Universal cables 12
Retrofi t and modernization components 14
COMPLETE line 16
Customer-specifi c products 18
Find out more
with the web codeFor detailed information, use the web codes provided in this
brochure. Simply enter # and the four-digit number in the search
fi eld on our website.
Web code: #1234 (example)
Or use the direct link:
phoenixcontact.net/webcode/#1234
The new standard for
the control cabinet.
More information on
pages 16 to 19.
4 PHOENIX CONTACT
Controller-specifi c system cabling – The wiring conceptVARIOFACE system cabling is a wiring concept that has been specially designed to
connect I/O modules from various automation devices. Plug-in components are used
here in place of conventional, complex, and error-prone single wires. As a result, you
benefi t from fast, easy, and error-free wiring.
Your advantages
Fast, error-free, and uniform wiring, thanks to pre-
assembled system cables
Individual design, thanks to modules in single, double
or three-conductor connection technology
Flexible connection with screw, spring-cage or Push-in
connection technology
Extremely versatile: selection of various module
functions with optional relay or feed-through coupling
Simple planning with confi guration cross list or online
confi gurator
Solutions for the following controller
manufacturers are available:
• ABB
• Allen Bradley
• Emerson
• Honeywell
• Phoenix Contact
• Mitsubishi Electric
• OMRON
• Schneider Electric
• Siemens
• Yokogawa
Web code: #1526
PHOENIX CONTACT 5
1) Front adapter
The front adapter patches the signals so that
complex wiring with single wires is not necessary.
Simply plug the adapter into the correct input/
output card of the controller.
2) System cable
The signals from the controller to the module are
patched through a pre-assembled system cable.
They are available in various versions (length,
number of positions, and shielding).
3) Modules
The module transmits the control and fi eld
signals. You can also benefi t from the diversity
of our product range in this area. The modules
are available in various connection technologies,
overall widths, and diff erent functions.
6 PHOENIX CONTACT
Channel-specifi c confi guration with
electromechanical and solid-state relays
Controller-specifi c system cabling with PLC-V8 adaptersThe system cabling adapter enables fast, error-free connection of relay modules to the
control level. This solution combines the product features of PLC-INTERFACE and
VARIOFACE system cabling. Depending on the switching requirement, the I/O module
enables a channel-specifi c confi guration, thanks to its modular design.
Your advantages
Quick and easy connection of the coupling level and
controller because wiring using single wires is no
longer necessary
High fl exibility, thanks to the modular design enabling
a channel-specifi c confi guration of the relay output
module
In the event of a service call, the relay modules can be
replaced without disconnecting the wiring
Clearly arranged wiring in the control cabinet, thanks
to the compact design
Sensor and actuator series enables direct connection
of supply and return conductors
1
4
3
2
3
PHOENIX CONTACT 7
A comparison of wiring options
Conventional wiring
Due to complex wiring using single wires,
conventional wiring of sensors and actuators
is complicated and time-consuming. This
graphic illustrates the potential savings you
could achieve by switching to a state-of-the-
art wiring solution from Phoenix Contact.
Potential distribution
with loop bridge
Wiring using single
wires between the
control and interface
levels
Potential terminal
blocks for signal
marshalling
including wiring
Effi cient wiring solution
The potential savings in the graphic above
are achieved as follows:
Wiring eff ort is reduced due to
the plug-in bridges for potential
distribution. They thus replace
loop bridges.
System cables are used to wire the controller.
This eliminates the need for complex wiring
using single wires.
The supply and return conductors can
be connected directly to the actuator
or sensor version of the relay module.
This eliminates the need for conventional
terminal blocks and the associated wiring.
8 PHOENIX CONTACT
Controller-specifi c system cabling for signal and power wiringUse the VIP power cabling universal front adapters to couple all signal types to your
SIMATIC S7-300 controller modules via Plug and Play. The adapter versions with
COMBI connector or free cable end are suitable for signal and power wiring.
Implement applications with various switching requirements reliably and fl exibly. You
also benefi t from the full scope of functions of the terminal block, thanks to fi eld-side
connection to the CLIPLINE complete terminal block range.
Your advantages
Reliable signal and power wiring up to
max. 250 V AC/DC, 6 A
Safe handling, thanks to touch-proof design
Maximum fl exibility, thanks to universal applications
Convenient wiring via Plug and Play: benefi t from a
universal 1:1 connection
Versatile connection technologies from the
CLIPLINE complete terminal block program
Plug-in connection
Finally, plug the COMBI connector
into the correct terminal blocks.
The signals can be assigned clearly
through the use of numbers.
Controller connection
You can connect the front adapter
corresponding to the number
of positions to all common
S7-300 modules and secure it
to the assembly using the latch
mechanism or mounting screw.
Web code: #1526
PHOENIX CONTACT 9
Wire all signal types
Flexible signal patching
The controller signals are patched
to a 20-pos. or 40-pos. cable with
an open end. This cable end can
be connected to terminal blocks
or other connections on-site.
Digital OUT
Max. 6 A 5 … 250 V AC/DC
Analog IN/OUT Digital IN
5 … 250 V AC/DC4 … 20 mA
10 PHOENIX CONTACT
Potential distributors and universal modulesThe universal VIP modules form the interface between the electronics and control
levels. They can be used in any application and enable the realization of space-saving
connections. Modules for signal transmission and potential distribution are available,
depending on the application.
Your advantages
Comprehensive collection of signals, thanks to several
potential levels
Clear separation of potentials, thanks to separate
supply for large conductor cross sections
Clear assignment of connection terminal blocks,
thanks to sequential marking
Whether for operating voltage distribution
or control voltage distribution, potential
distributors from Phoenix Contact are rated
up to 250 V/30 A, and can therefore be used
in many diff erent applications. They enable
simple, precise marshalling and distribution of
electrical signals in cramped spaces.
Web code: #2249
PHOENIX CONTACT 11
Your advantages
Space-saving, thanks to the compact design
Modules can be defi ned exactly, thanks to variable
marking
Monitoring function: also available with status
indicator
Diverse product range, thanks to the variety of
products
Universal modules
Universal modules from Phoenix Contact couple
connectors to screw or Push-in connection terminal
blocks 1:1, regardless of whether you are using FLK,
D-SUB, ELCO, DIN strips, or RJ45.
12 PHOENIX CONTACT
Universal cables for fast, error-free connectionYou only have to choose: Phoenix Contact provides various system cables for an
error-free 1:1 connection between the automation device and module. Whether with
IDC/FLK or D-SUB connectors, universal cables enable you to achieve fast wiring that
is protected against polarity reversal.
Your advantages
Outstanding service: standard lengths from 0.5 to
10 m as well as individual lengths
High current carrying capacity, thanks to the large
conductor cross section of each single wire
Flexible, thanks to free cable ends with single-wire
marking
PVC and halogen-free versions available
IDC/FLK connectors
Number of positions:
10, 14, 16, 20, 26, 34, 40, 50
Conductor cross section per wire:
0.14 mm2
Current carrying capacity per wire:
1 A
Web code: #2023
PHOENIX CONTACT 13
D-SUB connectors
Number of positions: 9, 15, 25, 37, 50
Conductor cross section per wire:
0.25 mm2
Current carrying capacity per wire: 2 A
Versions for D-SUB connectors
FemaleMale
14 PHOENIX CONTACT
Retrofi t and modernization componentsThe service life and availability of hardware is limited, especially for control systems.
When it becomes diffi cult and expensive to obtain replacement parts or a more
powerful system is required, you should consider retrofi tting or modernizing
your system.
Your advantages
Greater availability, thanks to short downtimes during
the migration process
Error-free connection, by retaining the existing fi eld
wiring
Reduced cabling eff ort, thanks to plug-in components
Reduced maintenance costs, thanks to ongoing
technological development of the system
Web code: #2250
PHOENIX CONTACT 15
1. Intermediate adapter
The S5 connector is plugged directly into the
I/O card via the intermediate adapter. A new
S7-400 is installed in place of the S5. The
existing fi eld wiring is retained.
3. Startup adapter
All signals of the existing S5 wiring are
extended using the universal startup adapters.
The free cable end can be connected to
diff erent controllers such as S7-400 or S7-300.
2. Conversion adapter
Conversion adapters connect the front
adapters to S7-300 I/O modules. Using the
adapters, the signals of the S5 front adapter
can be converted to a 50-pos. strip.
16 PHOENIX CONTACT
COMPLETE line – The comprehensive solution for the control cabinet COMPLETE line is a system comprising technologically leading and coordinated
hardware and software products, consulting services, and system solutions that help
you optimize your processes in control cabinet manufacturing. Engineering, purchasing,
installation, and operation become signifi cantly easier for you.
Web code: #2089
PHOENIX CONTACT 17
Your advantages in detail:
Comprehensive product portfolio
With COMPLETE line, we off er a complete
product portfolio of technologically leading
products. This includes:
• Controllers and I/O modules
• Power supplies and device circuit breakers
• Terminal blocks and distribution blocks
• Relay modules and motor starters
• Signal conditioners
• Safety technology
• Surge protection
• Heavy-duty connectors
Reduced logistics costs
Reduced variety of parts, thanks to
standardized marking, bridging, and testing
accessories. The COMPLETE line system
coordinates products, design, and accessories
so that you benefi t from maximum reusability
and thus reduce your logistics costs.
Intuitive handling
Thanks to the simple, intuitive handling of
the coordinated hardware components, you
will save time during installation, startup,
and maintenance. Push-in connection
technology enables you to wire applications
quickly – without using tools. The broad,
technologically leading product portfolio will
always provide you with the right product for
standard or special applications.
Optimized processes in control
cabinet manufacturing
COMPLETE line supports you, from
engineering through to manufacturing, in
designing your control cabinet production as
effi cient as possible. Thus, your customized
concept for optimizing your processes in
control cabinet manufacturing is created. Our
terminal strip production helps you to fl exibly
manage order peaks or to supply your control
cabinet production with fully assembled DIN
rails just in time.
Time savings across the entire
engineering process
The PROJECT complete planning and marking
software supports the entire process of
control cabinet manufacturing. The program
features an intuitive user interface that
enables the individual planning, automatic
checking, and direct ordering of terminal
strips.
The new standard
for the control cabinet
Discover the extensive COMPLETE line
product portfolio and fi nd out more about
COMPLETE line and your comprehensive
solutions for the control cabinet.
Visit our website:
phoenixcontact.com/completeline
18 PHOENIX CONTACT
Customer-specifi c products – From the enquiry through to the individual productCan't fi nd what you're looking for in our range? No problem! From small adjustments
to completely new product developments, the Phoenix Contact service team will cater
to your requirements. You can count on us: we have comprehensive technical expertise
and are extremely fl exible. We will work with you at every stage of the project to
develop your individual solution.
Web code: #2251
Your advantages
Personal consultation with a dedicated contact
partner for the duration of the entire project phase
Individual concept creation for your application
Fast, reliable handling by experienced specialists
Large and small series with professional quality
On-time delivery, thanks to precise planning and
project control
PHOENIX CONTACT 19
From the enquiry through to the
product
We will create versions from catalog products
or new products in accordance with your
specifi cations.
Your application requirements
We provide tailored cables based on pinning,
conductor cross-section, and various
connectors.
Customer-specifi c products
Together, we will fi nd an individual
solution: from the marking, through the
connection technology, right through to
PCB modifi cation.
Blomberg, Germany
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PHOENIX CONTACT GmbH & Co. KG
Flachsmarktstraße 8
32825 Blomberg, Germany
Phone: +49 52 35 3-00
Fax: +49 52 35 3-4 12 00
E-mail: [email protected]
phoenixcontact.com
You will fi nd our complete
product range at:
phoenixcontact.com
In dialog with customers and partners worldwide
Phoenix Contact is a globally present, Germany-based market leader. Our group
is synonym for future-oriented components, systems, and solutions in the fi elds of
electrical engineering, electronics, and automation. A global network across more than
100 countries, and 17,400 employees ensure a close proximity to our
customers, which we believe is particularly important.
The wide variety of our innovative products makes
it easy for our customers to fi nd future-oriented
solutions for diff erent applications and industries.
We especially focus on the fi elds of energy,
infrastructure, process and factory automation.
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