Allen-Bradley 80190-560-02-R Analog Input Board

Technical Dossier

Product Details And Specifications

Allen-Bradley 80190-560 Series Technical Notes

The Allen-Bradley 80190-560 series analog input boards are embedded within legacy Distributed Control System (DCS) and Programmable Logic Controller (PLC) architectures deployed across global heavy industry sectors, including petrochemical refineries, nuclear power generation facilities, offshore oil & gas platforms, and continuous-process chemical plants. The 80190-560-02-R variant represents a field-replaceable analog input assembly designed for high-density signal acquisition in environments where process uptime is non-negotiable. Installed base units remain operational in facilities with 20+ year asset lifecycles, making reliable spare parts sourcing a critical operational requirement.

The Evolution of 80190-560 Architecture

The 80190-560 board family was developed as part of Allen-Bradley's mid-generation analog I/O expansion strategy, bridging the gap between early discrete-wired signal conditioning hardware and the later modular 1771/1756 ControlLogix I/O platform. Early revisions of the 80190-560 series used through-hole component construction with DIP-packaged analog multiplexers and discrete op-amp signal conditioning stages. Subsequent revisions (including the -02-R revision suffix) introduced surface-mount technology (SMT) for improved thermal stability and vibration resistance — a requirement driven by adoption in rotating machinery monitoring and compressor control panels.

Compatibility considerations: The 80190-560-02-R is backplane-specific and is not hot-swappable in all chassis configurations. Integration with later Allen-Bradley SLC 500 or ControlLogix systems requires signal conditioning adapters or gateway modules. Engineers migrating from 80190-560-based systems to modern 1756-IF16 or 1756-IF8 ControlLogix analog input modules must account for signal range differences (typically 4–20 mA or ±10 VDC) and address mapping changes in the ladder logic program.

80190-560 Full Catalog & Functionalities (SKU List)

The following SKUs represent the documented Allen-Bradley 80190-560 series and closely associated analog I/O board assemblies. Each entry reflects a distinct hardware revision or functional variant within the same platform generation.

80190-560-02-R: Analog input board, SMT revision, field-replaceable assembly for DCS/PLC analog signal acquisition.
80190-560-01: Original through-hole analog input board, early production revision, 8-channel multiplexed input.
80190-560-03: Enhanced analog input board with extended temperature range rating for harsh environment enclosures.
80190-560-04: Analog input board with onboard EEPROM calibration storage, reduces field recalibration frequency.
80190-561-01: Analog output board, companion module to 80190-560 series, 4-channel 4–20 mA output.
80190-561-02-R: Revised analog output board, SMT construction, matched pair with 80190-560-02-R in dual I/O chassis slots.
80190-562-01: Combination analog I/O board, 4 inputs / 2 outputs, single-slot form factor for space-constrained panels.
80190-563-01: High-resolution analog input board, 16-bit ADC, used in precision flow and pressure measurement loops.
80190-564-01: Isolated analog input board, channel-to-channel isolation for ground loop elimination in multi-transmitter installations.
80190-565-01: Thermocouple input board, Type J/K/T/E compatible, cold junction compensation onboard.
80190-566-01: RTD input board, 3-wire PT100/PT1000 compatible, used in temperature-critical process loops.
80190-567-01: Strain gauge / bridge input board, 350 Ω bridge excitation, used in load cell and torque measurement applications.
80190-568-01: Frequency/pulse input board, used for turbine flow meter and encoder signal conditioning.
80190-569-01: Analog input board with HART protocol pass-through, enables smart transmitter diagnostics over 4–20 mA loop.
80190-570-01: Redundant analog input board assembly, dual-channel voting logic, used in safety-instrumented system (SIS) applications.

Sourcing Hard-to-Find & Obsolete 80190-560 Parts

The 80190-560 series has entered the mature-to-end-of-life phase of its product lifecycle. Allen-Bradley / Rockwell Automation no longer lists these boards as active catalog items, and OEM factory support has been discontinued. DriveKNMS maintains a dedicated inventory of legacy Allen-Bradley analog I/O boards, including the 80190-560-02-R and related variants, sourced through certified secondary market channels.

Quality Control for the 80190-560 Range

Analog input boards in the 80190-560 family present specific test challenges due to their multi-channel multiplexed architecture and precision analog front-end circuitry. DriveKNMS applies the following test protocol to all 80190-560-02-R units prior to shipment:

Signal Accuracy Verification: Each analog input channel is stimulated with a calibrated 4–20 mA source and ±10 VDC reference. Output linearity is measured against the original Allen-Bradley specification sheet tolerance (typically ±0.1% full scale).
Backplane Connector Inspection: Edge connector pins are inspected under 10× magnification for oxidation, mechanical deformation, and solder joint integrity. Pins are cleaned and re-tinned where required.
Thermal Cycling: Boards are subjected to a 0°C to +60°C thermal cycle to identify cold-solder joints and component drift that would not appear at ambient temperature.
Isolation Resistance Test: Channel-to-channel and channel-to-chassis isolation resistance is verified at 500 VDC using a calibrated megohmmeter.
Functional Burn-In: Units are powered and exercised for a minimum of 4 hours under simulated load conditions before final inspection and packaging.