AB FLEX I/O Remote I/O Adapter Module

AB FLEX I/O Remote I/O Adapter Module

Safety and Usage Precautions

Prohibited Scenarios: Do not use with Classic PLC-5/15 or PLC-5/25 processors.

Safety Guidelines: Solid-state devices have different characteristics than electromechanical devices and should be used in accordance 

with applicable safety guidelines; Rockwell Automation is not responsible for consequential damages.

Environmental Requirements: Suitable for use in pollution class 2, overvoltage category II industrial environments at altitudes up to 

2000 metres above sea level, Group 1, Class A industrial equipment, and in a suitable enclosure.

Static electricity protection: The equipment is sensitive to static electricity, anti-static measures are required during operation.

Other notes: There are strict requirements on the length of power supply wiring, grounding methods, preventing the entry of foreign objects, 

and avoiding electrically charged operation.

Approval for use in hazardous areas

Europe: The modules are approved for use in Zone 2 in Europe and are subject to specific requirements, such as UV protection and enclosure protection.

North America: Modules are approved for use in hazardous areas in North America, with product labelling ‘CL I, DIV 2, GP A, B, C, D’, 

and use is subject to temperature codes and combined equipment review.

Installation Steps

Pre-installation Preparation: Clearly identify components and understand standard addressing modes and substitution relationships.

Mounting to DIN rail: Hook adapter onto DIN rail and rotate down to ensure it locks into place, if not it can be done with a tool.

Replacement in an existing system: Remove the relevant parts in order, take care to align the slots when installing the new adapter, 

and reconnect the wiring when the installation is complete.

Wiring: Connect the remote I/O cable, power supply, pay attention to the location and order of wiring, if the last adapter needs to be terminated resistor.

Addressing mode setting: Select the addressing mode by setting S1 and S2 switches, different modes correspond to different switch settings, 

and need to re-power on after setting.

Practical Application Cases

Automobile production line: In the automobile production workshop, a large number of equipments need to be monitored and controlled in real time. 

For example, in the body welding process, many welding robots and sensors need to communicate with the control system. 

FLEX I/O Remote I/O Adapter Module can connect the digital input and output signals of the robot, such as controlling the start and stop of the welding gun, 

and monitoring the analogue signals of the welding current and voltage sensors. 

With its multiple addressing modes, it can be flexibly configured to address different devices and transmit data stably to the main control system via 57.6Kbps, 

115.2Kbps or 230.4Kbps communication rates, ensuring that the welding work is carried out accurately and improving production efficiency and product quality.

Chemical production process control: The chemical production environment is complex, with corrosive gases and potential explosion risks. 

For example, the 1794 - ASBK series E module (for hazardous gas environments) can be used for liquid material transport and reaction control. 

It connects flow sensors, pressure sensors to monitor the material flow, reactor pressure and other analogue signals, 

as well as digital signals to control the opening and closing of valves. By communicating with the control system, 

it regulates the production process according to the set parameters. Module grounding and protection design, 

with explosion-proof shell, can ensure stable operation in chemical hazardous environments 

and prevent safety accidents caused by electrostatic discharge and electrical failure.

Intelligent warehousing and logistics systems: In automated three-dimensional warehouses, shuttle cars, stacker cranes, 

and other equipment need to be controlled precisely, and the FLEX I/O remote I/O adapter module connects the equipment's motor drives, position sensors, 

etc. The module can, for example, be used to monitor the position of a stacker crane. 

For example, the digital signals from the position sensors of the stacker cranes are monitored to determine their position between shelves, 

and the module's communication function transmits the position information to the control system, 

which then controls the movement of the stacker cranes accordingly. 

Its flexible installation method and various wiring specifications facilitate installation and connection in the complex wiring environment of 

storage equipment to achieve efficient cargo storage and retrieval.

Parameter specifications

I/O Capacity: The I/O capacity of 1794-ASB/E and 1794-ASBK/E is 8 modules, while 1794-ASB2/D is 2 modules. This determines the number of FLEX I/O modules that can be connected to them. In industrial automation projects of different sizes, the appropriate model can be selected according to the actual equipment connection requirements. For example, for a small production line with relatively few devices, the 1794-ASB2/D may be able to meet the connection requirements, while a complex production line in a large factory involving the monitoring and control of many devices may require a module with a larger I/O capacity such as the 1794-ASB/E.

Power Requirements: All models require a power supply capable of delivering 23A (24V DC) with a 2ms start-up inrush current. The input voltage range is 19.2V...31.2V DC, within which the module can operate stably. Taking 1794-ASB/E as an example, the module can still work when the connected power supply voltage is at the lower limit of 19.2V, but if the voltage is continuously lower than this value, the performance may be unstable or even unable to work normally; if the voltage is higher than 31.2V, it may cause damage to the internal circuitry of the module. The output voltage is 5V DC, 640mA, which can provide stable working voltage for the connected FLEX I/O modules.

Communication Rate: 1794-ASB/E, 1794-ASBK/E and 1794-ASB2/D support three communication rates: 57.6Kbps, 115.2Kbps and 230.4Kbps. Users can flexibly choose the appropriate communication rate according to the requirements of real-time data transmission and the quality of the communication line in the actual application scenarios. For example, in the environment of low real-time data transmission requirements and certain interference in the communication line, the rate of 57.6Kbps can be selected to ensure the stability of data transmission; while in the very high real-time requirements, such as some high-speed operation of the equipment monitoring scenarios, you can choose the high speed rate of 230.4Kbps, to ensure that the data is transmitted in a timely and accurate manner.

Indicator Lights: All of them are equipped with power (green), adapter activity (green), adapter failure (red), local failure (red) indicator lights. These indicators provide visual feedback on the module's operating status. When the power indicator lights up green, it indicates that the module has been connected to a normal power supply; the adapter activity indicator flashes green, indicating that the module is carrying out normal data communication activities; if the adapter failure indicator turns red, it means that the module may have internal faults that need to be investigated in a timely manner; and the local fault indicator turns red, suggesting that there may be a problem with the locally-connected device or line.

Dimensions: Dimensions (H x W x D) are 87 x 69 x 69mm (3.4 x 2.7 x 2.7 inches), the compact size makes it easier to install and arrange in control cabinets and other space-limited environments, space-saving, and easy to integrate with other equipment.

Isolation Voltage: Isolation voltage is 50V (continuous), basic insulation type, tested at 750V DC for 60s (between power supply and system, power supply and RIO, RIO and system). This electrical isolation design effectively prevents electrical interference between different circuits, protects the module and connected devices from electrical shocks and interference, improves the stability and reliability of system operation, and ensures safe operation in complex industrial electrical environments.