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Industrial Automation & Network Hardware
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The 1794 FLEX I/O vs FLEX 5000

May 29, 2025

Allen-Bradley’s 1794 FLEX I/O and the newer FLEX 5000 I/O systems are modular distributed I/O solutions engineered to reduce panel space, simplify wiring, and enhance system flexibility. While 1794 FLEX I/O has been a proven solution in industrial automation for decades, FLEX 5000 I/O builds on this legacy with advanced features, security, and environmental robustness. This guide offers a detailed, categorical comparison to help engineers choose the best fit for their applications.

Environmental Specifications and Safety Certifications

1794 FLEX I/O

  • Operating Temperature: 0°C to 55°C (standard), -20°C to 70°C (XT version)

  • Storage Temperature: -40°C to 85°C

  • Shock Tolerance: 30g (operating), 50g (non-operating)

  • Vibration: 5g RMS @ 10Hz to 500Hz

  • Humidity: 5% to 95% non-condensing

  • Certifications: CE, UL, cUL, C-Tick, ATEX, ODVA, SIL2

FLEX 5000 I/O

  • Operating Temperature: -40°C to 70°C

  • Storage Temperature: -40°C to 85°C

  • Shock Tolerance: 30g (operating and non-operating)

  • Vibration: 5g RMS @ 10Hz to 500Hz

  • Humidity: 5% to 95% non-condensing

  • Certifications: CE, Ex, SIL3, PLe, G3 coating (XT models), Class 1 Div 2, c-UL-us

Conclusion: FLEX 5000 offers broader environmental resilience and higher safety integrity levels.

Network Adapters and Communication

FLEX 5000 I/O Adapters

  • Ethernet/IP support at 10/100/1000 Mbps

  • Models include: 5094-AENTR, 5094-AEN2TR, 5094-AENSFPR, etc.

  • Redundancy: Supports DLR and PRP

  • Security: Explicit & Implicit Protected Modes

  • Time Sync: Supports CIP Sync & PTP

  • Studio 5000 support (v31+)

  • SFP options for copper/fiber networks

FLEX 1794 I/O Adapters

  • Ethernet/IP (10/100 Mbps), ControlNet, DeviceNet

  • Models: 1794-AENTR, 1794-ACN15, 1794-AND, etc.

  • Uses TCP/UDP over CIP

  • Studio 5000 & RSLogix 5000 support (v20+)

Conclusion: FLEX 1794 offers protocol flexibility; FLEX 5000 delivers speed, security, and redundancy.

HART I/O Module Comparison

1794 FLEX I/O

  • Models: 1794-IE8H, 1794-OE8H

  • Protocol: HART V5/V6

  • 8 analog I/O per module

  • Supports basic diagnostics and firmware filtering

FLEX 5000 I/O

  • Models: 5094-IF8IH, 5094-OF8IH, XT versions

  • Protocol: HART V5/V6/V7 + HIH (Highly Integrated HART)

  • Channel-isolated analog I/O

  • Advanced diagnostics, readback, and configuration via Studio 5000 (v32.02+)

Conclusion: FLEX 5000 HART modules are more intelligent and support PlantPAx integration.

Specialty and Safety Modules

1794 FLEX I/O

  • Specialty Modules: High-Speed Counter, Frequency, Pulse Counter

  • Safety: Limited, SIL2 certified

FLEX 5000 I/O

  • Specialty Modules: High-Speed Counter

  • Safety: Full suite of SIL3, PLe-rated Safety I/O modules

  • Supports RIUP, Thermocouple, RTD

Conclusion: FLEX 5000 excels in integrated safety and modern specialty modules.

Ease of Integration and Flexibility

1794 FLEX I/O

  • Legacy system with wide install base

  • Interoperable with ControlNet, DeviceNet, EtherNet/IP

  • Flexible network protocol choice

FLEX 5000 I/O

  • Advanced features for modern Ethernet/IP architectures

  • Interchangeable adapters in Studio 5000

  • Better suited for redundant, high-speed applications

Final Verdict Choose 1794 FLEX I/O if you need:

  • Cost-effective solution

  • Multi-protocol support (DeviceNet, ControlNet)

  • Proven legacy compatibility

Choose FLEX 5000 I/O if you need:

  • High-speed, redundant EtherNet/IP networking

  • Enhanced safety and diagnostics

  • Compatibility with modern control platforms like ControlLogix 5580

For tailored recommendations, contact:

PLG Automation
Email: sales@plgautomation.com
Phone: 800-906-9271