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.

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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: info@phoenixcontact.com

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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