How to Facilitate Re-use of Field Wiring in Control System Upgrades

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Phoenix Contact Electronics GmbH

PHOENIX CONTACT Deutschland GmbH

If the new S7 controller operates perfectly with the existing field wiring, it can be moved into the existing cabinet as a replacement for the old S5 controller, with a standard adapter replacing the special commissioning adapter. In the unlikely event of a problem, it takes only seconds to unplug the S7 module and revert everything to its previous state.

In some cases the dimensions of the new S7 modules may make it impossible to use one-piece adaptors with S5-115U or S5-135U front connectors. In this case the solution is to use changeover adapters installed in a separate rack.

The changeover adapter accommodates the S5 front connector, with its connected field wiring, and links this to a 50-pin terminal strip. Pre-assembled round cables from Phoenix Contact then couple the 50-pin terminal strip to the new S7 module. During commissioning, the pluggable nature of the connection again makes it possible to switch from the S5 to the S7 controller and back again within just a few seconds.

Use System Cabling for Flexibility

System extensions and upgrades are especially easy if the existing system was installed using Phoenix Contact’s system cabling solutions. The range of system cabling components includes front adapters which integrate the I/O signals via plug connectors, pre-assembled and tested system cables in all lengths, and interface modules that can be snapped onto mounting rails. The interface modules convert the I/O signals from plug connectors with high pin counts to terminals. Individual conductors are then used to make connections between the field and marshaling levels.

Since all the system cabling components are upward-compatible, only the front adapters need to be changed when the control system is upgraded. The system cables and interface modules remain in place, and are simply connected to the new S7 modules via custom-fit front adapters.

These migration techniques allow users to profit from the rapid rewiring of the very many I/O modules installed in every plant, as well as being able to continue using their existing field wiring. Since pre-wiring can be done in the workshop, the application can be retrofitted within a short time.

One user commented: “In just four months we migrated our S5 controls, which were installed in nine cabinets, to S7 devices without any downtime. The complete retrofit and all the necessary function tests were performed at weekends.” ●

* The author is responsible for Product Marketing Cabling, Phoenix Contact Electronics GmbH, Bad Pyrmont, Germany.

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