Belden AF100 9688 0101000 Retrofit-Ready Shielded Cable

Belden AF100 9688 0101000 Retrofit-Ready Shielded Cable for AF100 Series Control Systems

The Belden AF100 9688 0101000 is a high-performance shielded control cable engineered for seamless integration into legacy and modern industrial automation environments. Whether you are replacing a discontinued cable run in an aging control cabinet, upgrading signal wiring across a DCS backbone, or migrating from an older fieldbus topology to a more current communication architecture, this cable delivers the electrical characteristics and mechanical durability required for mission-critical retrofit projects. With 100% shield coverage, low capacitance, and robust insulation rated for industrial environments, the AF100 9688 0101000 is a trusted choice for system integrators and maintenance engineers working under tight downtime constraints.

In retrofit scenarios, cable selection is often the most overlooked variable. Engineers focused on replacing a legacy PLC — such as moving from an older Allen-Bradley SLC 500 rack to a ControlLogix L7x controller — frequently underestimate the impact of signal cable integrity on I/O accuracy and communication stability. The Belden AF100 9688 0101000 addresses this directly: its foil-plus-braid shield construction suppresses EMI interference that commonly affects analog input modules, encoder feedback lines, and serial communication links in environments with variable-frequency drives, servo amplifiers, and high-current motor starters operating in close proximity.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

A successful cable retrofit begins well before the first conduit is opened. When planning a wiring upgrade in a control cabinet housing a Siemens S7-300 or S7-400 rack, the first step is to audit the existing cable schedule against the current I/O list. Cables serving analog input modules — such as the SM 331 or SM 334 — are particularly sensitive to shield integrity, and any degradation in the existing run will manifest as signal drift or noise on the engineering station. Replacing these runs with the Belden AF100 9688 0101000 restores baseline signal quality without requiring changes to the module configuration or the STEP 7 hardware catalog entry.

For projects involving communication cable replacement, the AF100 9688 0101000 is well-suited for PROFIBUS DP trunk segments connecting remote I/O stations — for example, a Siemens ET 200M distributed I/O rack or a Beckhoff EK1100 EtherCAT coupler used in a hybrid migration architecture. When replacing PROFIBUS cable, engineers must verify that the new cable’s characteristic impedance (nominally 150 Ω for PROFIBUS DP) and capacitance per unit length remain within the network’s design budget, particularly on long trunk segments exceeding 50 meters.

In control cabinets undergoing a full modernization — replacing an aging GE Fanuc Series 90-30 rack with a PACSystems RX3i controller — the cable retrofit often runs in parallel with backplane and power supply replacement. The 24 VDC power supply feeding the I/O rack must be re-evaluated for current capacity when new modules with higher inrush are introduced. Similarly, terminal block wiring from the field device side must be re-terminated to match the new module’s connector pitch. The Belden AF100 9688 0101000 accommodates standard ferrule terminations compatible with Phoenix Contact PTFIX and Weidmuller WDU terminal blocks commonly found in these cabinets.

HMI communication links are another area where cable quality directly affects retrofit outcomes. When migrating from a legacy Siemens OP7 or OP17 operator panel to a modern KTP700 Basic or TP1200 Comfort panel, the RS-485 or MPI cable connecting the HMI to the PLC CPU must be replaced to support the new panel’s communication parameters. The AF100 9688 0101000 provides the shielding and impedance characteristics needed for stable MPI and PROFIBUS communication at the distances typical of machine-level HMI installations. After cable replacement, engineers should verify the HMI project’s connection settings — baud rate, station address, and network profile — match the CPU configuration before going live.

For I/O expansion projects adding a new Mitsubishi MELSEC Q-series extension base or an Omron CJ-series I/O rack to an existing control system, the inter-rack communication cable and power distribution wiring must be carefully selected. The AF100 9688 0101000 is suitable for the signal wiring between the main rack and expansion units, provided the cable routing avoids parallel runs with high-voltage power cables. Maintaining a minimum separation of 200 mm between signal and power cable trays is standard practice in IEC 61439-compliant panel builds and should be enforced during the retrofit installation.

Downtime Control During System Migration

Minimizing production downtime during a cable retrofit requires a structured pre-outage preparation strategy. Before the scheduled maintenance window, engineers should complete a full point-to-point continuity check of the existing cable schedule, photograph all terminal block wiring, and export the current PLC program — including force tables and data block values — to a backup file on the programming laptop. For Siemens S7 projects, this means saving the full STEP 7 or TIA Portal project with all hardware configuration data. For Allen-Bradley systems, an RSLogix 5000 or Studio 5000 ACD file backup should be verified against the controller’s online program before the outage begins.

During the outage, a phased cable replacement approach reduces risk. Rather than pulling all cables simultaneously, replace one signal group at a time — starting with the least critical analog inputs — and perform a point-to-point verification at the terminal block before reconnecting the module. This approach allows the control system to be partially restored and tested in sections, reducing the total time the process is offline. For systems with redundant I/O or hot-standby CPU configurations, the migration can often be performed with zero unplanned downtime by switching to the standby path while the primary wiring is replaced.

After all cables are replaced and terminated, a structured commissioning sequence should be followed: power up the I/O rack, verify module status LEDs, force each I/O point from the programming terminal, and confirm field device response before releasing the system to automatic control. Communication links — PROFIBUS, DeviceNet, or EtherNet/IP — should be verified using the network diagnostic tools available in the PLC programming environment. Any address conflicts or duplicate station numbers introduced during the retrofit must be resolved before the system is returned to production.

Retrofit Support FAQ

Q1: Is the Belden AF100 9688 0101000 a direct drop-in replacement for the original AF100 series cable?
A: Yes. The AF100 9688 0101000 maintains the same conductor configuration, gauge, and shield construction as the original AF100 series specification. No changes to terminal block wiring or module configuration are required for a like-for-like replacement. Engineers should verify the conductor count and color coding against the existing cable schedule before installation.

Q2: What commissioning checks are required after replacing the cable in a live control system?
A: After installation, perform an insulation resistance test between each conductor and the shield, verify shield continuity from end to end, and confirm that the drain wire is grounded at one end only. For analog signal runs, compare the live signal reading at the PLC input module against the field instrument output to confirm signal integrity. For communication cables, use the PLC’s network diagnostic function to verify all remote stations are online and error-free.

Q3: Can this cable be used for PROFIBUS DP and RS-485 communication runs?
A: The AF100 9688 0101000 is suitable for RS-485 and PROFIBUS DP applications where the cable’s characteristic impedance and capacitance per unit length are within the network’s design budget. For PROFIBUS DP, the cable should be verified against the EN 50170 Type A cable specification for the intended segment length and baud rate. At baud rates above 1.5 Mbps, only Type A cable is recommended for segments longer than 10 meters.

Q4: What warranty coverage is provided, and what does it include?
A: All units ship with a 12-month warranty from the date of shipment. The warranty covers manufacturing defects in materials and workmanship. Each unit undergoes pre-shipment testing including continuity verification and insulation resistance measurement. Warranty claims are processed through SMARTNEXMSK’s technical support team, and replacement units are dispatched within 3 business days of claim approval.

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