Molex Brad HarshIO 600 User manual

HarshIO 600

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User’s Manual

HarshIO 600

IP67 Motor Drive Roller IO Module for

EtherNET/IP

Brad™ from Molex

Version 1.4

October 24

th

, 2018

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Revision History

Date

Author

Changes

Revision

May 22

th

, 2018

Samuel Savary

Initial version

1.0

June 5

th

, 2018

Samuel Savary

Fixing information added (Dimension chapter)

1.1

July 2

sd

, 2018

Samuel Savary

MOD Led behavior & Operating temperature

1.2

October 9

th

, 2018

Youssef Ouassif

- Dynamic Braking of Itoh Denki motor

- General diagnostic on Drive rollers added to

Web Server

- Minor changes

1.3

October 24

th

, 2018

Samuel Savary

Interroll & Itoh Denki speed table update

1.4

Although every effort has been made to ensure the accuracy of this document, all information is subject to

change without notice. Molex takes no liability for any errors in this document or for direct, indirect, or

consequential damage resulting from the use of this manual.

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STATEMENT OF LIMITED WARRANTY

Brad™ from Molex, manufacturer of HarshIO products, warrants to Buyer that products, except software,

manufactured by Brad™ will be free from defects in material and workmanship. Brad™ obligation under this

warranty will be limited to replacing the defective parts within one year of the date of purchasing. Products may

be returned by Buyer only after permission has been obtained from Brad™. Buyer will prepay all freight

charges to return any products to the facility designated by Brad™.

Brad™ further warrants that any software supplied as part of a product sale, except obsolete products, will be

free from non-conformances with Brad™ published specifications for a period of 90 days from the time of

delivery. While Brad™ endeavors to improve the features and performance of software associated with its

products, no effort on the part of Brad™ to investigate, improve or modify HarshIO modules firmware at the

request of a customer will obligate Brad™ in any way.

For the convenience of existing customers, Brad™ continues to supply certain products that are classified as

obsolete. No warranty on the software features of these products is stated or implied and Brad™ specifically is

not obligated to improve the design of these products in any way. Information about the status of any product

is available upon request and customers are advised to inquire about the status of older products prior to

making a purchase.

This limited warranty does not cover losses or damages which occur in shipment to or from Buyer or due to

improper installation, maintenance, misuse, neglect or any cause other than ordinary commercial or industrial

applications. In particular, Brad™ makes no warranties whatsoever with respect to implied warranties of

merchantability or fitness for any particular purpose. All such warranties are hereby expressly disclaimed. No

oral or written information or advice given by Brad™ or Brad's representative shall create a warranty or in any

way increase the scope of this warranty. This limited warranty is in lieu of all other warranties whether oral or

written, expressed or implied. Brad’s liability shall not exceed the price of the individual units, which are the

basis of the claim. In no event shall Brad™ be liable for any loss of profits, loss of use of facilities or device, or

other indirect, incidental or consequential damages.

Although every effort has been made to ensure the accuracy of this document, all information is subject to

change without any notice. Brad™ takes no liability for any errors in this document or for direct, indirect, or

consequential damage resulting from the use of this manual.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many

variables and requirements associated with any particular installation, Brad™ cannot assume responsibility or

liability for actual use based on the examples and diagrams.

COPYRIGHTS and TRADEMARKS

Reproduction of the contents of this manual, in whole or in part, without written permission of Brad™ is

prohibited.

Mini-Change

®

, Ultra-Lock

™

, Brad™ are all registered trademarks of Molex, Inc.

All other products or trademarks are the property of their respective owners.

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Table of contents

1. General Safety Instructions ................................................................ 6

General information ................................................................................................. 6

Personnel qualifications .......................................................................................... 6

Preventive messages .............................................................................................. 6

Usage compliance ................................................................................................... 6

Device installation and set-up ................................................................................. 7

Device operation ..................................................................................................... 8

Electrical, mechanical and thermal specifications ................................................... 8

Preventive and corrective maintenance .................................................................. 8

2. General description ............................................................................. 9

Introduction .............................................................................................................. 9

Overview ............................................................................................................... 10

3. Technical Data ................................................................................... 17

Dimensions (mm) .................................................................................................. 17

Power Data ............................................................................................................ 18

Electrical Signal Data ............................................................................................ 18

EtherNET/IP .......................................................................................................... 20

Mechanical and Environmental Data .................................................................... 21

4. System Description ........................................................................... 22

Physical description............................................................................................... 22

Power connector ................................................................................................... 23

Ethernet connectors and encoding switches ........................................................ 26

I/O connectors ....................................................................................................... 30

MDR connectors .................................................................................................... 32

Protective and functional earth connection ........................................................... 34

5. I/O Data mapping ............................................................................... 36

I/O Messaging ....................................................................................................... 36

EtherNet/IP Assembly instances ........................................................................... 37

Assembly #101 – Input Process & Error Status Data ........................................... 38

Assembly #102 – Input Process, Error Status & Operating information Data ...... 39

Assembly #103 – Output Process & Control Data ................................................ 40

Assembly #104 – Output Process / Control Data & Reset Operating information 43

Assembly #105 – Configuration Data .................................................................... 44

6. MDR Features & Behaviors ............................................................... 44

MDR Startup .......................................................................................................... 44

MDR Operating Speed .......................................................................................... 45

7. Getting started ................................................................................... 46

Packaging content ................................................................................................. 46

Out of box settings ................................................................................................ 46

Connection instructions ......................................................................................... 46

Rockwell Studio 5000 ............................................................................................ 47

8. Web Server Interface ......................................................................... 48

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Hardware/Firmware Module information ............................................................... 48

Ethernet network information ................................................................................ 49

EtherNET/IP diagnostic information ...................................................................... 50

Event logger .......................................................................................................... 51

Power supply information and channel status ...................................................... 52

Motorized Drive Roller information ......................... Error! Bookmark not defined.

Energy ................................................................................................................... 57

9. EtherNet/IP Object Classes ............................................................... 58

Identity (0x01) ........................................................................................................ 58

Message Router (0x02) ......................................................................................... 60

Assembly (0x04) .................................................................................................... 61

Connection Manager (0x06) .................................................................................. 62

TCP/IP Interface (0xF5) ........................................................................................ 63

Ethernet Link (0xF6) .............................................................................................. 64

File (0x37) ............................................................................................................. 65

DLR (0x47) ............................................................................................................ 66

QoS (0x48) ............................................................................................................ 67

10. Firmware update ................................................................................ 68

11. Product Support ................................................................................ 68

Technical Support ................................................................................................. 68

Web Site ................................................................................................................ 69

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1. General Safety Instructions

General information

The current documentation is intended for persons technically qualified to install, use and service the products

described herein. It contains the necessary information for proper use of the products. However, for advanced

use of our products, please contact your nearest dealer for additional information.

The content of this documentation is not binding and cannot extend or limit warranties.

Personnel qualifications

Only qualified persons are authorized to install, use and service the products. Use by unqualified persons or

failure to follow the safety instructions of this document, the manuals and/or those affixed to the devices, can

result in irremediable harm or damage to persons and equipment. The following personnel are deemed to be

qualified persons for:

• Equipment operation: Personnel who operates the machines and/or processes connected to the

Brad™ products. Brad™ HarshIO must be used by persons who have received training and have

been informed of the major risks involved in working in an industrial environment.

• Preventive and corrective maintenance: Persons who modify Brad™ products hardware and software

configuration and install the product updates supplied by the manufacturer. These persons must:

o be trained in Brad™ products and operation

o have the experience and technical knowledge required to be aware of the risks (electrical

hazards in particular) involved in their job and the ways of reducing these risks for

themselves, third parties and the equipment being used.

Preventive messages

Preventive messages are designed to identify the particular risks likely to affect personnel and/or hardware.

Different message types, both in the documentation and on the products, indicate different degrees of risk:

Danger messages indicate immediate hazards that could result in death or serious injury if not averted.

Warning messages indicate situations that could result in death, serious injury or material damage.

Caution messages indicate potentially dangerous situations that could cause bodily harm or material damage.

Usage compliance

The products described in the current documentation comply with currently applicable European

Directives (EC labeling). However, they can only operate correctly with the applications for which they were

intended as described in the documentation, and with approved products.

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As a general rule, if all the handling, transportation, and storage recommendations and installation, operation

and maintenance instructions are followed, the products will operate correctly without risk for personnel or

hardware.

Device installation and set-up

It is important to follow the rules below when installing and setting up the Brad™ HarshIO. If system installation

includes products more than thirty meters away from each other, the basic cabling rules must be closely

followed.

• Strict compliance with the safety instructions provided in this documentation or on the equipment to be

installed and implemented, is absolutely essential.

• Make sure that the installation is carried out in compliance with regulations of the user country,

• Install the equipment in a suitable environment. As a closed equipment, the Brad™ HarshIO may be

installed in two ways:

o In a casing (cabinet, chest) or,

o Directly without any additional protection, if the associated systems (power supply, cables,

sensors, etc.) already carry a protection index equivalent to IP67 or higher.

Always connect the Brad™ HarshIO to the protective earth (PE) in compliance with existing standards (for

example: use the green/yellow wires in accordance with the NFC 15 100 standard).

• LV (Low Voltage) circuits must have a protective earth connection to ensure dangerous voltage

detection.

• Before powering up the device, check that the nominal voltage is the same as the mains voltage.

• Only use Extra Low Voltage power supplies (PELV-/SELV-) which comply with existing standards.

• Check that the power voltages are within the tolerance ranges defined in the technical specifications

for the devices.

• Always ensure that power restoration (immediate, hot or cold) will not create a hazard for personnel or

equipment.

• Ensure that emergency stop devices remain effective in any equipment operation mode, even when

abnormal (for example, in the event of a cut wire). Resetting these devices should not result in

uncontrolled or undefined restarts.

• Position the signal cables so that the automation functions will not be disrupted by any capacitive,

inductive or electromagnetic influences, etc.

• Install the automation devices and their controlling devices so that they are protected against any

adverse incident.

• Adequate safety precautions must be applied to inputs and outputs to prevent the lack of signals from

causing undefined states in the automation devices.

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IP67 MDR for EtherNET/IP

Device operation

Because Brad™ HarshIO devices are components of a control system, the safety of the entire automated

system, including that of the installation and the application, cannot be dealt with in this document. For further

information, see IEC 61131-4, describing risk reduction measures for PLC users.

See the documentation of the specific products involved for more information on operation safety.

Electrical, mechanical and thermal specifications

Detailed information about the electrical, mechanical and thermal specifications of the device is available in the

associated technical documentation (installation manuals, service instructions).

Preventive and corrective maintenance

Servicing

• When replacing parts or components, only use factory approved parts.

• In all cases, before servicing a Brad™ HarshIO, disconnect the power supply from the device (unplug

the power cord or open the power cut-out device).

• Before servicing an onsite mechanical Brad™ HarshIO, disconnect its power supply and mechanically

lock the moving parts.

• On positive logic outputs or negative logic inputs, take all the necessary precautions to prevent any

disconnected wires from coming into contact with the mechanical ground (risk of unwanted

commands).

Product end-of-life

Contact your local dealer for information on how to dispose of used products in compliance with current

regulations.

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2. General description

Introduction

Brad™ HarshIO 600 EtherNET/IP Motorized Drive Roller IO module (also called HarshIO) is a reliable

solution for connecting industrial controllers to Motor Drive Rollers & I/O devices in harsh duty environments.

Contained in an IP67 rated housing, Brad I/O modules can be machine mounted and are able to withstand

areas where liquids, dust or vibration may be present. This makes them ideally suited for many applications

including material handling and automated assembly.

All Brad™ HarshIO modules, with Micro-Change

®

(M12) ports,

accept both standard threaded cordsets and the Molex

Ultra-Lock™ system.

Ultra-Lock™ connection System! The fastest, easiest and most

secure connection ever designed. Ultra-Lock™ technology is

designed for higher performance and reliability. Discover how the

push-to-lock technology of the Ultra-Lock connection system can

eliminate your downtime, increase your productivity and lower your

costs. More information visit: www.molex.com .

Brad™ HarshIO includes advanced diagnostic features. Each module embeds visible LEDs to provide

maintenance personnel the ability to easily determine I/O module and network status. These statuses are also

available through the process data image or via extended slave diagnostics.

Brad™ HarshIO main features include:

▪ Module is housed in an IP67 rated enclosure that when properly installed—according to IEC 60529—

provides protection against the ingress of dust, water

▪ 8 digital user configurable I/O channels (DIO) + 4 ports for Interroll or Itoh Denki Motor Drive Roller

control.

▪ 4 or 5-pole Mini-Change (7/8) power supply connector

▪ Digital input and output short circuit protection

▪ Integrated 2-port unmanaged Ethernet switch with cross-over and MRP capabilities

▪ Diagnostic visible LEDs

▪ Rotary switches for IP address, firmware update and factory reset modes

▪ ODVA Conformance tested

▪ Certifications:

o CE compliant for all applicable EC directives

o FCC Title 47, Part 15, Subpart B, Class A

o Protection against electrical shocks IEC 61131-2:2007 Chap 12/13/14

o EMC directive for industrial use

o UL94-V1

o ODVA certified

Part Number Table

SAP No

Material No

Description

112095-5156

TCDEI-8YMP-DYU-G

IP67 module for EtherNET/IP, 4-pin power supply connector with

Isolated grounding, 8 digital user configurable I/O channels

(DIO) + 4 ports for Interroll & Itoh Denki Motor Drive Rollers

control.

112095-5157

TCDEI-8YMP-D1U-G

IP67 module for EtherNET/IP, 5-pin power supply connector with

Isolated grounding, 8 digital user configurable I/O channels

(DIO) + 4 ports for Interroll & Itoh Denki Motor Drive Rollers

control.

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Overview

The HarshIO module is consisted of three main parts.

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Power distribution

HarshIO module can be powered up through 4/5-pole Mini-Change (7/8”) male power supply connector. It can

supply or transfer total amperage of 8A per pin.

The maximum power cable length shall be 30 meters. This is a recommendation

but not a limitation. The module will still work if the cable is longer. The danger is

potentially to destroy the module if a lightning occurs (very rare).

It can be powered by 2 separate power supplies:

• UB power supply is used to power:

o Module’s logic

o Sensor power (Pin 1)

o Digital Inputs / Outputs channels (C0 to C7)

• UL power supply is used to power the motor drive rollers

o

There is no separate grounding between UB and UL. It means that 0V (UB) and 0V (UL) are connected.

The +24 voltage can be applied on UB and UL from separate or unique power supply source.

Note!

UB & UL support a power interruption according to EN 60204-1.

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Network topologies

HarshIO EtherNET/IP modules can be used with a protocol compliant controller as part of control system

architecture. The built-in unmanaged 2-port Ethernet switch allows flexibility in the network topology to meet

your application needs. These topologies include the following:

• Star

• Daisy-chain

• Ring (using DLR protocol)

• Combination of all above

Star topology

Star topology allows you to connect mixed I/O modules or additional equipment. This topology allows

maintenance on one module – for example, by removing the network cable, or by power cycling to the module

– without affecting the other modules.

HMI

Ethernet

Switch

PLC

Daisy-chain topology

The daisy-chain topology allows you to connect I/O modules or additional equipment in one line, from one

device to the next in an optimized way along the production line.

When considering the daisy chain topology, note that

• If a module, somewhere in the middle of the chain, has the network cable disconnected or power to the

module is removed then communications to any module located down the chain will be lost.

• The embedded dual port Ethernet switch located in each module eliminates the need for additional

Ethernet switches.

HMI

Ethernet

Switch

PLC

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Ring topology

Ring topology allows you to include mixed HarshIO modules and additional devices in a ring. Performing

maintenance on one module – for example, by removing the network cable, or by removing a module – does

not affect other modules as the disruption can be detected and the EtherNET/IP communication can be then

routed adequately. To manage the ring, a protocol called DLR (Device Level Ring) is required.

Note

When considering DLR ring topology:

A device called DLR Supervior shall be present in the ring to control the

administration and detects the network failures. The other participants are

called DLR Devices.

Combination of various topologies

Combining star and daisy-chain topologies allows you to connect HarshIO modules with mixed HarshIO

modules or additional network devices.

HMI

Ethernet

Switch

PLC

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Signal

The HarshIO module supports up to 8 I/O ports:

• 4 I/O ports with 8 standard input / Output user configurable channels. (C0 to C7).

• 4 M ports for Motor Drive Roller (M0 to M3).

The I/O ports with configurable digital output on Pin 2 / Pin 4 can deliver up to 2A (4A Peak) for actuators with

high power requirements.

The M port for Motorized Drive Roller (MDR) can control the following rollers:

• Interroll EC310

• Itoh Denki PM500XE / PM500XP

Only 1 MDR can be connected on each M port. Up to 4 Interroll EC310 or 4 Itoh Denki PM500XE/XP can be

connected at the same time (See below). But no mixed Interroll / Itoh Denki MDR configuration is supported.

4 I/O configurable ports

4 Motor Drive Roller ports

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Typical application

Brad® MDR Conveyor Classic HarshIO Modules provide a reliable solution when connected with commonly

used 24V DC Motorized Drive Rollers (MDR’s).

Contained in an IP67 rated housing, Brad® MDR Conveyor Classic HarshIO Modules can withstand areas

where liquids, dust or vibration may be present, making them ideal for use in material handling applications.

For general motorized roller conveyor, it avoids protecting the IO module and its wiring by an enclosure

constructed with conveyor frame and frame cover conform to UL50 Type 1 or greater.

NOTE

The MDR can be connected to the M port via 5 wires M12/M8 converter cable with a

maximum length of 3m.

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3. Technical Data

Dimensions (mm)

The following figures show the external dimensions of the I/O module.

NOTE

When fixing the MDR module, tighten all the four screws otherwise the module may be

greatly affected by vibration, causing failure of the module. When installing the module,

tighten screws within the following torque range:

- M4 Mounting screw: 0.83 to 1.11 Nm.

- M3 Screw for a Functional Earth metal fitting: 0.43 to 0.57 Nm.

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Power Data

Module

4/5-pin power version

Power IN connector

Mini Change (7/8”), 4/5-pin, male, Maximum 8 A

Module & Input power (UB)

24 VDC, -20%/+25% (19.2 VDC / 30 VDC) protected against power crossing)

Warning, a voltage over 30 VDC may destroy the module

Operating current (UB)

90 mA (no I/O device connected)

Operating current (UL)

20 mA (no I/O device connected)

Max current consumption (UB)

8.2 Amps

Output Power (UL)

24 VDC, -10%/+10% (21.6 VDC / 26.4 VDC) for Itoh Denki

24 VDC, -10%/+10% (21.6 VDC / 28 VDC) for Interroll

(protected against power crossing)

Warning, a voltage over 30 VDC may destroy the module

Max current consumption (UL)

8.2 Amps

Galvanic isolation between UB & UL

500 V min

Electrical Signal Data

I/O Ports

Max draw current per I/O ports

4 A

Sensor power pin

Pin 1 (L+ / Sensor power supply)

Sensors draw current from

UB

Sensors draw current (Pin 1)

200mA Nominal / 400mA Peak

Channels

Pin 2 (configured as)

Pin 4 (configured as)

Standard Digital Inputs

Number of Channel

4 channels max

Input type

PNP, compliant to IEC 61131-2 Type 3

On-state current

2.5 mA typ.

Off-state current

1 mA max.

Input channel voltage (“1”)

10 V … 30 V

12 V … 30 V

Input channel voltage (“0”)

-5 V … 5 V

-5 V … 9 V

Input filter

1ms

Standard Digital Outputs

Outputs draw current from

UB

Channels

4 channels max

Output voltage (min)

UB – 1V

Output type

PNP, current sourcing

Output current

2 A per channel (4A peak)

Maximum output current

8.0 A at 25°C: total for all outputs combined

8.0 A at 25°C: total for all outputs combined with

all sensor supply current

Short circuit current (typical)

up to 6.5 A

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MDR ports

MDR port

Pin 1 (UL)

Pin 2 (output)

Pin 3 (GND)

Pin 4 (I/O)

Pin 5 (analog)

Operating current

2A nominal / 6A peak

24mA nominal

/

24mA nominal

/

Operating voltage

+24VDC

/

+24VDC

0-10VDC

Input type

/

PNP, compliant to

IEC 61131-2 Type 3

/

Output type

/

PNP, current sourcing

/

PNP, current

sourcing

/

Warning!

The digital outputs of the product are internally protected against voltage spike due to

inductive load switching. Nevertheless, an external protection (freewheeling diode)

could be added if necessary.

Note!

Shields of I/O connectors are not connected to earth. If shielded cable is used, then

customer should connect the cable shield to the earth.

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EtherNET/IP

EtherNET/IP Fieldbus

Ethernet connectors

2 x M12, 4-pin, female, D-Coded, shielded

IP setting

DHCP (based on MAC & on Client_ID), Static IP, Stored IP

Protocol

EtherNet/IP Adapter according specification Vol 1-3.17 (CIP) and Vol 2 – 1.18 (EtherNet/IP)

Data access

Implicit messages for I/O data transfer

Communication Class

Real Time Conform Class B (RT CC-B) – No IRT supported

Implicit (I/O) connection

• 1x Exclusive Owner (EO) connection (with configuration data only)

• Up to 7 Listen Only (LO) connections (with or without configuration data) • Up to 8 Input

Only (IO) connections (with or without configuration data)

• 8 simultaneous connections (Ex: 1EO+ 4IO +3LO)

Explicit (EM) connection

Up to 8 Class 3 connections (Connected and unconnected)

Supported CIP Objects

• 0x01 – Identity

• 0x02 – Message Router

• 0x04 – Assembly

• 0x06 – Connection Manager

• 0xF5 – TCP/IP Interface

• 0xF5 – Ethernet Link

• 0x37 – File (EDS Upload)

• 0x47 – DLR

• 0x48 – QoS

Integrated Switch

• 2x ports integrated switch (with MRP capability)

• Speed: 100Mbps

• Auto negotiation

• Auto crossing

• Auto polarity

• 1x status Led / port

• Storm Protection against network loop (Broadcast, Multicast and Unicast packets)

Ethernet Packet

Manage up to 9000 packet/sec

Request Packet Interval (RPI)

from 1 ms up to 65535 ms (default 30 ms)

IP Address Conflict Detection

Yes

Quick Connect

Yes

DLR (Device Level Ring)

Yes (Ring Node, Beacon-Based)

QoS (Quality of Service)

Yes (Layer 3 supported only)

ODVA conformance

Yes (CT15)

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Molex Brad HarshIO 600 User manual

Molex Brad HarshIO 600 User manual

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