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I am in the middle of doing a retrofit for a old PLC5 and i decided to upgrade it to a Control Logix. With how much I/O I was needing the price of the system was going to be very pricey. So I decided to use my main rack as a control logix and use Flex I/O for my remote racks. I have never put together a Flex I/O rack so I am unsure of what I need for this rack other than my I/O modules and a communication module. Could someone give me a list of what is needed for these systems? 

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Sounds like you are going in the right direction.  The flex is an older remote i/o system but it is solid and I prefer it over point I/O or remote racks.  If you use the AENT communication module then you can just drop it off of an ethernet I/P connection which is fairly straight forward.  In addition to the I/O modules, you will need compatible terminal bases such as the TB3.  Each I/O module will need to be evaluated for compatibility to the proper terminal module, but the I/O documentation is detailed about which modules pair with which terminal blocks.  I would stay away from the 32 point modules as the wiring is less straight forward.  The 16 point discrete modules and 8 point analog modules make wiring pretty intuitive.  You get 8 modules per drop so you will need to plan accordingly on that. 

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Posted (edited)

@PLCMentor.comHow do these modules connect together? It doesn't seem like they require a chassis or anything like that. From what I can tell they all kind of just snap together and you din rail mount them. And as of power supplies I am assuming that each set of 8 that I have will require there own power supply? 

Edited by AkumaShi

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We've used Flex IO extensively and can vouch for its longevity and sturdiness.

The terminal bases snap onto DIN rail side-by-side and have a sliding connector that engages the unit to the left. Then the I/O module snaps into the terminal base.

They have an -AENTR module that's a dual-port communications module that would let you daisy chain the racks on Ethernet/IP instead of making home runs to switches.

Example:
The 1794-IA16 module (16-point 120VAC input module) uses the 1794-TB3 terminal base. You would need a 1794-AENT or -AENTR for each Flex chassis. If you have sufficient 24VDC power available where each chassis is to be mounted, you don't need a power supply.

Their "Integrated Architecture Builder" is very helpful when you're trying to figure out what "supporting components" you need for a particular platform. It's part of their product selection toolbox which can be downloaded here:

https://www.rockwellautomation.com/global/support/product-selection-configuration/overview.page?pagetitle=Control-Systems-Configuration-Tools&docid=01503dfdb8a20bf09c86944a6f44364b

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