molex TCDEC-8B4P-DYU-G8, TCDEC-8B4P-D1U-G8, TCDEC-8B4B-D1U-G8, TCDEC-8B4B-D1U-GW, TCDEC-8B4P-D1U-GW Original Instructions Manual

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1  IP67 Safety Digital I/O Modules

User’s Safety Manual

‘ORIGINAL INSTRUCTIONS’

EtherNet/IP™ CIP Safety™ HarshIO

IP67 Digital I/O Modules

Brad™ from Molex

Version 1.2

June 06th, 2017

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Revision History

Date

Author

Changes

Revision

February 04, 2016

E. Gory

Release version

1.0

May 19, 2016

E. Gory

 Page 34 – Output sourcing - Update wiring schematic with

24 VDC on Pin1

 Page 42 – Add 5-pole product references  Page 84 – Add product code in decimal  New “Safety I/O connections” chapter  Update template of “Declaration of Conformity” (DoC)

1.1 June 06, 2017

E. Gory

 Page 27 – Update concerning the safety classes  Page 42 – Add important note when UB is in overvoltage  Page 61 – Correction of 5-pole power connector wiring  Page 80 – Correction of the default Gateway address

when using the static IP method

 Page 136 – Update of the Safety Reset procedure

1.2

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 the 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 installation. Products may be returned by Buyer only after permission has been obtained from Molex. 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 the Buyer or due to improper installation, maintenance, misuse, neglect or any cause other than ordinary commercial or industrial applications. 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 equipment, 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 Molex 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. About This Manual ............................................................................... 8

About this manual .................................................................................................... 8

2. General Safety Instructions .............................................................. 11

Intended use .......................................................................................................... 11

Responsibility of the user ...................................................................................... 11

Documentation ...................................................................................................... 12

Maintenance .......................................................................................................... 12

Spare parts ............................................................................................................ 12

Shipping ................................................................................................................ 12

Disposal ................................................................................................................. 13

Education of the personnel ................................................................................... 13

Personal protective equipment .............................................................................. 13

Special hazards ..................................................................................................... 14

Sign-posting .......................................................................................................... 15

3. Product Overview .............................................................................. 16

Introduction ............................................................................................................ 16

Functional safety - safety relevant parameters ..................................................... 18

Product environmental and safety instructions ..................................................... 19

Product features .................................................................................................... 21

Ultra-Lock M12 connectivity .................................................................................. 21

Ordering information.............................................................................................. 22

Ethernet topologies ............................................................................................... 23

4. Functional Safety Functions ............................................................. 27

Safety States ......................................................................................................... 27

Safety Inputs ......................................................................................................... 28

Safety Sourcing Outputs (TCDEC-8B4P-D1U-Gx and TCDEC-8B4P-DYU-Gx) .. 33

Bipolar Safety Outputs (TCDEC-8B4B-D1U-Gx and TCDEC-8B4B-DYU-Gx) ..... 37

I/O Status .............................................................................................................. 39

Behavior in case of fault ........................................................................................ 39

Response Time ..................................................................................................... 41

5. Product Characteristics .................................................................... 42

Hardware characteristics ....................................................................................... 42

Mechanical characteristics .................................................................................... 47

Physical I/O mapping ............................................................................................ 48

Safety I/O assemblies ........................................................................................... 49

Safety I/O connections .......................................................................................... 50

Safety I/O data mapping ....................................................................................... 52

Pin assignment ...................................................................................................... 60

LED assignment .................................................................................................... 62

6. Product installation and wiring ........................................................ 66

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Power supply ......................................................................................................... 66

Ethernet connection .............................................................................................. 67

Module grounding .................................................................................................. 70

I/O wiring ............................................................................................................... 71

7. Product Deployment .......................................................................... 78

Getting Started ...................................................................................................... 78

IP address setting .................................................................................................. 78

EDS files ................................................................................................................ 85

Import HarshIO Safety EDS into Rockwell hardware description library .............. 89

Configure HarshIO Safety module into Rockwell RSLogix 5000 project .............. 97

Safety I/O assemblies ......................................................................................... 100

Configure HarshIO Safety module in Molex SNCT ............................................. 103

Connection and testing of HarshIO Safety module in RSLogix 5000 ................. 119

8. EtherNet/IP Behavior ....................................................................... 122

I/O behavior ......................................................................................................... 122

IDLE behavior ...................................................................................................... 122

Duplicate IP address ........................................................................................... 122

EtherNet/IP Object Classes ................................................................................ 123

9. Product Replacement ...................................................................... 131

Before to start ...................................................................................................... 131

Replacement procedure ...................................................................................... 132

Verification ........................................................................................................... 133

10. SNCT Configuration Software ........................................................ 134

Overview ............................................................................................................. 134

Safety Reset ........................................................................................................ 136

Lock / Unlock Configuration ................................................................................ 142

Stored IP Address using DHCP Server............................................................... 149

IP Address Conflict .............................................................................................. 155

Ethernet Port Diagnostics ................................................................................... 156

Module Information .............................................................................................. 157

Set/Reset password ............................................................................................ 159

Additional Information.......................................................................................... 162

Download Firmware ............................................................................................ 164

Print module configuration .................................................................................. 169

Log (Emergency Mode) ....................................................................................... 172

11. Product Package .............................................................................. 173

Product package ................................................................................................. 173

USB Stick ............................................................................................................ 173

Memory Key ........................................................................................................ 174

12. Web Server Interface ....................................................................... 176

How to connect the web server ........................................................................... 176

General information ............................................................................................. 177

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Diagnostic information ......................................................................................... 178

13. Selection of Cables and Cordsets .................................................. 180

Overview ............................................................................................................. 180

14. Certifications .................................................................................... 181

TUV Certificate .................................................................................................... 182

EU Declarations of Conformity ............................................................................ 183

15. Product Support .............................................................................. 185

Warranty conditions ............................................................................................. 185

Product Information ............................................................................................. 185

Technical Support ............................................................................................... 186

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1. About This Manual

This Safety Manual describes the IP67 digital safety I/O modules (also called HarshIO) from Molex.

About this manual

Chapter 1: About This Manual

This is this present chapter.

Chapter 2: General Safety Instructions

This chapter gives an overview of all important safety aspects for optimum protection of the personnel, as well as for the safe and fault-free operation.

Chapter 3: Product Overview

This chapter gives an overview of the product usage and main features.

Chapter 4: Safety Functions

This chapter gives a presentation of the characteristics of the Safety Inputs and Safety Outputs of the module.

Chapter 5: Product Characteristics

This chapter gives an overview of characteristics and technical data of the HarshIO safety modules.

Chapter 6: Product Installation and Wiring

This chapter details the wiring possibilities and associated safety categories.

Chapter 7: Product Deployment

This chapter presents an example of how to proceed with the commissioning of the HarshIO Safety modules based on the Rockwell Automation RSLogix™ 5000 software version 20.

Chapter 8: Product Behavior

This chapter gives a presentation of HarshIO safety modules behaviors related to EtherNet/IP communication.

Chapter 9: Product Replacement

This chapter describes the strategy in case of replacement of commissioned HarshIO Safety modules.

Chapter 10: SNCT Configuration software

This chapter presents the important features that are available in the SNCT software used for the HarshIO module commissioning.

Chapter 11: Product Package

This chapter details the contents of the product package.

Chapter 12: Web Server Interface

This chapter presents the HarshIO information available by connecting the module web server.

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Chapter 13: Selection of cables and cordsets

This chapter presents how to access to a selection of connectivity products and associated part numbers to help designing the system infrastructure.

Chapter 14: Certifications

This chapter describes how to identify the product and contact information the technical support.

Chapter 15: Product Support

This chapter describes how to identify the product and contact information the technical support.

Target audience

The manual is targeted at users who have a background in automation and networking technology, including safety application, EtherNet/IP™ and CIP Safety™.

Structure of the manual

The manual consists of chapters. Every chapter provides a self-contained description of a specific topic.

Availability

The manual is available in electronic form as PDF-file (Adobe Acrobat Reader) in English language. It is important to warrant that the product will be implemented by a body having the right skill to understand English. In case of concern, this document could be on request translated to a different language. Nevertheless the English version will remain the reference in case on hazardous translation.

Icon headings

Important passages in the text are highlighted by following icons and headings:

Danger!

Immediate danger to life and limb of personnel and others. Non-compliance will cause death or serious injury.

Warning!

Hazardous situation to life and limb of personnel and others. Non-compliance may cause death or serious injury.

Attention!

Designates a possibly harmful situation. Non-compliance can damage the product or something in its environment.

Note!

Supplementary information and useful tips.

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Liability Limitation

All data and notes in these instructions were prepared with consideration to the statutory standards and regulations, the present state of technology, as well as our many years of knowledge and experience.

The manufacturer accepts no liability for damage caused because:

 Non-compliance with the instructions  Non-specified use  Use of untrained personnel

The actual scope of delivery can, by special designs, deviate from the explanations and presentations given here, because of the utilization of additional order options, or because of the most recent technical changes.

The user is responsible for the execution of service and commissioning according to the safety instructions of the prevailing standards and other relevant national and local instructions concerning conductor dimensioning and protection, earthing, overcurrent protection and so on.

The individual, who has carried out the mounting or the installation, is liable for damages which result from the mounting or from the connection.

We have checked the contents of this manual for agreement with the hardware and software described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularly. Necessary corrections are included in subsequent editions.

Suggestions for improvement are welcome.

The manufacturer is no liable for damage resulting from missing or insufficient knowledge of the manual. Therefore, it is recommended to the operator to obtain written instructions from qualified people.

Modifications or functional alterations on the product are not allowed due to safety reasons. Any modification on the product not explicitly authorized by the manufacturer will result in loss of any liability claims to the vendor. The same applies if non authorized parts or equipment are used.

This manual is to be treated confidentially. It has been provided only for the personnel, which uses the product. The transfer of this document to third parties without the authorization in writing of the vendor is prohibited.

Note!

The contents, texts, drawings, pictures and any other illustrations are copyrighted and subject to other protection rights. Any person unlawfully using this publication is liable to criminal prosecution.

Use of this manual

This safety manual contains information for the intended use of the HarshIO safety modules.

Knowledge of regulations and the proper technical implementation of the safety instructions detailed in this manual performed by qualified personnel are prerequisites for safely planning, engineering, programming, installing and starting up the HarshIO safety modules as well as for ensuring safety during their operation and maintenance.

Molex will not be held liable for severe personal injuries, damage to property or the surroundings caused by any of the following: unqualified personnel working on or with the devices, de-activation or bypassing of safety functions or failure to comply with the instructions detailed in this manual.

The manual contains safety instructions, description of the modules and information about life cycle.

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2. General Safety Instructions

This chapter gives an overview of all important safety aspects for optimum protection of the personnel, as well as for the safe and fault-free operation.

Intended use

The modules have been engineered and designed exclusively for the proper use described in this documentation. The modules are intended to be used if considering all references and information of this manual.

Warning! Danger by not intended use!

Each use of the product, which differs from the intended use, can lead to dangerous situations.

Therefore: Use the product only as intended. Use the product only together with the recommended components. Consider all the data in this manual. Ensure that only qualified personnel works with the product. Ensure during configuration that the product is operated within its specifications. Ensure that the power supply corresponds to the given specifications. Only use the product in a technically adequate condition. Only use the product in combination with approved components.

Changes and modifications at the product

To avoid endangerments and to ensure the optimal operating, neither changes nor modifications should be made to the product, which are not specially approved by the manufacturer.

Responsibility of the user

The product is used in the factory automation environment. The user of the product is subject of the statutory duties to work safely.

In addition to the safety instructions in this manual, for the usage environment of the product, adhere to the relevant accident prevention and environmental protection regulations.

 The user must be informed about the valid industrial safety regulations in order to evaluate additionally

dangers, which arise as a result of the special conditions for the product in the place of operation. This is to be transcribed with working instructions for the operation of the product.

 These working instructions must be kept in the direct environment of the product and accessible at any

time for people who work with the product.

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 Fully adhere to the working instructions.  The product is only to be operated in a technically flawless and reliable condition.

Documentation

Every person working with the product must have read and understood the operating instructions before carrying out any work. The manual must be available to all personnel involved in:

 project design  installation  commissioning  operation  decommissioning

The following conditions must be met before using or commissioning the components described in this manual

Warning!

 Modification to the process control system should only be carried out when the

system has been disconnected from power!

 Installation and modifications shall only be performed by properly trained personnel  The national rules and regulations of the respective country must be satisfied

(installation, safety, EMC ...)

Danger!

To prevent hazards and ensure optimum performance, no changes, modifications or conversions may be made to the product that have not been expressly approved by the manufacturer.

Maintenance

The corresponding safety module is maintenance-free.

Spare parts

Please use only original spare parts of Molex.

Warning!

Incorrect or faulty spare parts can cause damage, malfunction or failure as well as affect security and safety function.

Shipping

For shipping always use the original packaging.

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Disposal

National rules and regulations apply to the disposal of the unit. Please check with the local authorities for the correct local disposal procedures.

Education of the personnel

Warning! Risk of injury resulting from insufficient qualification!

Improper use can cause considerable personal injury and material damage.

Qualification

The automation system may only be operated by persons, which are trained, instructed and authorized. Troubleshooting, maintenance, cleaning, and replacement must be performed only by skilled or trained personnel.

Qualified personnel

These persons have to know the instruction manual and have to act accordingly. Commissioning and training should only be performed by qualified personnel.

Operating personnel

These are electrical engineers and electricians of the customer or third party, which are authorized by the manufacturer and which have learned installation and commissioning by the manufacturer and are allowed to ground, mark and install electrical circuits and devices in accordance to the standard safety technology.

Qualified personnel is trained and instructed according to the corresponding valid standards in safety technology in the care and use of appropriate safety equipment.

Personal protective equipment

During work, the wearing of personal protective equipment is needed to minimize health hazards.

 Always wear the necessary protective equipment for the corresponding job.  For your own safety regard the signs, which are in your work space.

Work clothing

is close-fitting clothing with low tensile strength, with tight sleeves and without a protruding part. Depending on the application it should be prevented, that the carrier gets serious injured or is exposed to health risk during work.

For reasons of injury no jewelry like rings and chains should be worn.

Protective helmet

for protection against falling and flying objects.

Safety shoes

for protection against falling heavy objects.

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Protective gloves

To protect hands from friction abrasions, punctures or injuries, as well as from contact with hot objects

Eye protector

To protect eyes from flying parts and liquid splashes

Special hazards

In the following section the residual risks are identified, which result from the hazard analysis. Regard the listed safety warnings here and the notes in the whole manual to reduce health hazards and to

avoid dangerous situations.

Electric current

Danger! Risk of death by electric current!

Contact with live parts is immediate danger to life. Damage of the insulation or of components can be danger to life.

Therefore: Immediately turn off the power supply when the insulation is damaged. Work on the

electrical system only by qualified personnel. Always power-off and secure the electrical system during work.

Risk by residual energy

Danger! Risk of death by electric current!

After disconnecting the device from main voltage, parts such as power connections should only be touched when the capacitors are discharged in the device.

Therefore: Regard discharge time of the capacitors; do not touch live parts before having observed

a period of 1 minute. If there are additional connected capacitors on the link, the discharge of the link can last

considerably longer. In this case you have to determine the required waiting period or even to measure whether the device is safe.

Moving objects

Warning! Risk of injury from moving parts!

Rotary and linear moving parts can cause serious injuries.

Therefore: Do not touch moving parts during operation. Do not open the cover during operation. The mechanical residual energy depends on the application.

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Driven components rotate respectively move for a certain time even after switching off the power supply.

Fire fighting

Danger! Risk of death by electric current!

Risk of an electrical shock when using a conducting firefighting medium.

Therefore use the following firefighting medium:

 ABC powder / CO2

Behavior with dangers and accidents

Preventive measures

 Always be prepared for accidents or fire!  Keep first-aid equipment (first aid kit, blankets etc.) and fire extinguishers handy.  Make personnel familiar with accident message, first aid and rescue mechanisms.

In case of emergency: act correctly

 Set immediately the device with emergency stop out of operation.  Initiate first-aid measures.  Rescue persons from the danger zone.  Inform responsible on-site.  Call medical and / or fire department.  Clear the access routes for emergency vehicles.

Sign-posting

Warning! Danger of injury by illegible symbols

In course of time stickers and symbols on the equipment can get dirty or otherwise become unrecognizable.

Therefore: Please always maintain all safety warnings and operation instructions on the device in

easily readable condition.

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3. Product Overview

This chapter gives an overview of the product usage and main features.

Introduction

EtherNet/IP™ CIP Safety™ Brad™ HarshIO modules provide a reliable solution for the monitoring of safety input devices (interlock switches, emergency stops, light curtains, laser scanners …) as well as the control of safety output devices (relays, muting lamps, fail-safe motor starters…) with industrial safety controllers in harsh duty environments. Contained in an IP67 rated housing, Brad HarshIO can be machine mounted and are able to withstand areas where liquids, dust or vibration may be present.

EtherNet/IP™ CIP Safety™ HarshIO module serves mainly applications for automotive manufacturers and machine builders looking for on-machine safety I/O connection to reduce cabinet space. The IP67 60mm housing with M12 connectors make HarshIO modules ideally suited for many safety applications including material handling equipment, automated assembly machinery and automotive applications running robots into cells.

- Example of safety application used for automotive assembly line -

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The combination of EtherNet/IP and CIP Safety protocols allow exchanging safety process I/O and diagnostics information over a single Ethernet network. The modules need to be configured in order to suit with the safety function definitions, up to SIL 3 as defined by IEC 61508 or CAT 4/ PLe as defined by ISO 13849-1 (in particular, inputs and outputs could be set for use as dual-channel).

The diagram below shows some examples of safety I/O wirings.

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Functional safety - safety relevant parameters

This chapter describes parameters associated to functional safety. In according to IEC 61508, Safety means first that a system is free from unwarrantable risks. Functional safety is a part of the total safety, which guarantees the fail-safe response of a safety system according to the input conditions. Here internal safetyrelevant device errors must be detected and lead to a safe condition.

Safety relevant parameters may always be found in the according manuals of the modules.

TCDEC-8B4P-D1U-Gx and TCDEC-8B4P-DYU-Gx products:

Parameters according to IEC 61508

Meaning

PFH = 1 *10

-10

Probability of failure per Hour: Probability of danger failure per hour

PFDavg = 8.74 * 10

-06

Probability of Failure on Demand average: Average of probability of failure on demand

SFF according SIL 3

Safe Failure Fraction: Fraction of failure, which lead to a safe state.

TCDEC-8B4P-D1U-Gx and TCDEC-8B4P-DYU-Gx products:

Parameters according to IEC 61508

Meaning

PFH = 8.67 *10

-11

Probability of failure per Hour: Probability of danger failure per hour

PFDavg = 7.65 * 10

-06

Probability of Failure on Demand average: Average of probability of failure on demand

SFF according SIL 3

Safe Failure Fraction: Fraction of failure, which lead to a safe state.

All products:

Parameters according to DIN EN ISO 13849-1

Meaning

MTTFd: High

Mean Time To dangerous Failure

DCavg: High

Diagnostic Coverage average

Service Life: 20 years

During the expected life of the device of up to 20 years, no proof test is required

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Product environmental and safety instructions

Approvals, directives, standards

The HarshIO safety module has been designed to comply with the following directives and standards:

Conformity and approval

CE*

2006/42/EC

Machinery directive

2011/65/UE

RoHS 2 directive

2014/30/EU

EMC directive for industrial use (Class-B)

UL Listed

UL 508

Approval for USA and Canada

IEC 61508

Ed 2010

Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems (E/E/PE, or E/E/PES)

ISO 13849-1

Ed 2015

Safety of machinery

IEC 62061

Ed 2012

Safety of machinery: Functional safety of electrical, electronic and programmable electronic control systems

IEC 61131-2

Ed 2007

Programmable logic controllers - Equipment Requirements and Tests

ODVA conformance

Vol 2 – 1.18

EtherNet/IP™

Vol 5 – 2.6

CIP Safety™

IEC 60529

Ed 2010

IP67 degree of protection

*CE Declaration of conformity can be found in section ‘Certifications’ of this manual

The HarshIO has been designed and produced specifically for:

 communication and process control  general control and automation applications  industrial applications  operation within the environmental conditions specified in the technical data

This product was EMC tested for use in industrial areas. If it is to be used in personal or business and trade environments, the resulting system must go through EMC qualification.

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Explosive environments

Danger!

This device is not certified for applications in

 explosive environments (EX-zone)

Power supply and Electrical safety

The device is developed for operation on 24 VDC power supplies, which correspond to the PELV-/SELV regulations in accordance to EN 50178.

Risk of injury by electric current!

There may only devices be connected to the module, which have a safe separation from the mains (such as 120V/230V/600V) power.

The power supply to generate 24 V power must correspond to the requirements for PELV/SELV according to EN 50178.

IP67 rating

The product complies with IP67 when installed. All caps of non-used connectors shall be mounting on the product to maintain the IP67 rating during operation.

Danger! Risk of electric power!

Contact with live parts is immediate danger to life.

Mission time

The expected life time of the HarshIO module is up to 20 years with no proof test necessary.

Warning!

If the user calculates their safety application with the specified data for >20 years, the HarshIO has to be decommissioned and replaced. A proof test cannot be established by the user.

Earthing

Warning!

Connections to earth shall be wired accordingly to the relevant chapter of this manual in order to warrant EMC characteristics of the product.

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Product features

EtherNet/IP CIP Safety HarshIO main features include:

 Safety Inputs

o To connect safety devices, such as emergency stop push buttons, gate switches, and safety light

curtains.

o Single or dual channel modes supported. o Dual-channel mode evaluates consistency between two input signals (channels), which allows

use of the module for Safety Category 3 and 4. The time of a logical discrepancy between two channels can be monitored using a discrepancy time setting.

o Each safety input has its own associated test output to check external wiring short-circuit. o Independently adjustable ON and OFF delay are available per channel.

 Test Outputs

o Separate test outputs are provided for external short circuit detection of a safety input. o Power (24 V) can be supplied to devices, such as safety sensors. o Test outputs can be configured as standard non-safe outputs. o 2 test outputs can be used for broken wire detection of a muting lamp.

 Safety Outputs or Bipolar Safety Outputs

o Up to 1A for safety outputs and up to 2A for bipolar per output point. o Dual-channel mode evaluates consistency between two output signals (channels). o Safety outputs can be pulse tested to detect field wiring shorts to 24 VDC. o Bipolar safety outputs use pulse testing to detect a short to 24 VDC on the safety sourcing output,

and a short to 0VDC on the safety sinking output.

 I/O Safety RPI with up to 10ms cycle time  IP67 rated enclosure that when properly installed provides protection against the ingress of dust, water  Integrated 2-port unmanaged Ethernet switch with cross-over and DLR capability  Isolated grounding to able to use 2 separate power supplies to energize the module logic/inputs and

outputs.

 Protective earth (for power supplies)  Functional earth (for Ethernet connectors)  Diagnostic visible LEDs  Easy commissioning via Molex Safety Network Configuration Tool (SNCT)  On-board memory key (Window or M8 versions) allowing to store module configuration and perform

replacement in few minutes without any special tool or re-commissioning.

 3 rotary switches to set IP address

Ultra-Lock M12 connectivity

HarshIO safety modules with Micro-Change® (M12) ports accept both threaded cordsets and 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 the downtime, increase the productivity and lower the costs. More information visit: www.molex.com.

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22  IP67 Safety Digital I/O Modules

Ordering information

This user safety manual applies to the following HarshIO product references:

Part Number Table

4-pin 7/8” power connector versions

SAP No

Material No

Description

112095-5107

TCDEC-8B4P-DYU-GW

EtherNet/IP CIP Safety IP67 module, 4-pin power connector,

12 Safety Inputs + 4 Safety Outputs, Windows key

112095-5127

TCDEC-8B4P-DYU-G8

EtherNet/IP CIP Safety IP67 module, 4-pin power connector,

12 Safety Inputs + 4 Safety Outputs, M8 key

112095-5108

TCDEC-8B4B-DYU-GW

EtherNet/IP CIP Safety IP67 module, 4-pin power connector,

12 Safety Inputs + 2 Safety Bipolar Outputs, Windows key

112095-5128

TCDEC-8B4B-DYU-G8

EtherNet/IP CIP Safety IP67 module, 4-pin power connector,

12 Safety Inputs + 2 Safety Bipolar Outputs, M8 key

5-pin 7/8” power connector versions

SAP No

Material No

Description

112095-5111

TCDEC-8B4P-D1U-GW

EtherNet/IP CIP Safety IP67 module, 5-pin power connector,

12 Safety Inputs + 4 Safety Outputs, Windows key

112095-5129

TCDEC-8B4P-D1U-G8

EtherNet/IP CIP Safety IP67 module, 5-pin power connector,

12 Safety Inputs + 4 Safety Outputs, M8 key

112095-5112

TCDEC-8B4B-D1U-GW

EtherNet/IP CIP Safety IP67 module, 5-pin power connector,

12 Safety Inputs + 2 Safety Bipolar Outputs, Windows key

112095-5130

TCDEC-8B4B-D1U-G8

EtherNet/IP CIP Safety IP67 module, 5-pin power connector,

12 Safety Inputs + 2 Safety Bipolar Outputs, M8 key

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Ethernet topologies

EtherNet/IP CIP Safety HarshIO IO module can be used with a protocol compliant scanner as part of control system architecture. The modules built-in 2-port Ethernet DLR capable switch allowing to use the network topology that meets the application needs. These topologies include the following:

 Star  Daisy-chain  Combination of star and daisy-chain  DLR for Ethernet media ring redundancy

Star topology

Star topology allows to connect mixed I/O modules or additional devices. Performing maintenance on one module – for example, by removing the network cable, or by cycling power to the module – does not affect other modules.

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Daisy-chain topology

Daisy-chain ring topology is the easiest way to add more EtherNet/IP CIP Safety HarshIO IO module or additional devices in the system by daisy-chaining, or connecting each industrial device in series to the next.

This topology is the simplest and cost-effective solution because it takes full advantage of the dual port Ethernet switch integrated in HarshIO modules and reduces the overall Ethernet cable length.

Note!

When considering the daisy chain topology, note that:

 Performing maintenance on any module not physically located at the end of the

daisy chain – for example, by removing the network cable, or by cycling power to the module – affects any modules located down the chain from the maintained module.

 The embedded dual port Ethernet switch located in each module eliminates the

need for additional Ethernet switches

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25  IP67 Safety Digital I/O Modules

Combination of star and daisy-chain topology

Combining star and daisy-chain topology allows connecting EtherNet/IP CIP Safety HarshIO IO modules with mixed HarshIO modules or additional devices.

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26  IP67 Safety Digital I/O Modules

DLR Ring topology

DLR ring topology allows including mixed I/O 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 CIP safety communication can be then routed adequately.

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4. Functional Safety Functions

EtherNet/IP CIP Safety HarshIO modules can achieve the following safety classes by making suitable parameter settings and wiring.

Safety Classes

I/O Configuration

Per IEC 61508 / IEC 62061

Per ISO 13849-1

Dual I/O Channel

SIL 3

PL e / Cat. 4

Single I/O Channel

SIL 2

PL d / Cat. 2

Safety States

The safety states of the HarshIO module are defined as the following:

 Safe Outputs are switched OFF  Safe Inputs are reported in the OFF state on the network

Warning!

HarshIO modules are to be used in systems where the OFF state is the safety state.

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Safety Inputs

Safety inputs are used to report the state of safety input devices.

A safety input can be configured as:

 Not Used (default) - the input is disable and doesn’t participate in any safety function  Safety - the input participates to the safety function, but does not have a dependency on a test output  Safety Pulse Test - the input participates to the safety function and has a dependency on an

associated test output configured as “Pulse Test”

 Standard - The input doesn’t participate in any safety function (allows to connect non-safe input

device). Nevertheless a Standard input behaves exactly like an input configured as Safety.

Using Safety Inputs on Single-Channel

The inputs are configured as 2 distinct safety inputs on the same M12 connector.

The process Input value is set to safety device physical input value and status is “1” (good) as long as no fault is detected. On fault detection, the process Input value is turned OFF and status is “0” (bad).

HarshIO behavior when used as single safe inputs:

Safety Device

Physical State

Fault Detected

(1)

Safe Input

Process Value

Safe Input

Process Status

Safe Input

Led Status

0 = OFF

0 (safe)

OFF

1 = ON

1 (active)

YELLOW

0 = OFF

Yes

0 (fault)

(2)

RED

1 = ON

Yes

0 (fault)

RED

Notes!

 (1) When single channel input is configured as “Standard” or “Safety”, only internal

hardware faults can be detected. Input shall be configured as “Safety Pulse Test” to allow external short to ON detection.

 (2) This state is a transitory state only as it corresponds to fault reset condition

(physical value set to OFF). If physical fault still exist on the wiring, fault will be detected again at next ON transition.

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Using a Test Output

A test output can be configured as

 Pulse Test – When the external contact of the safety device is closed, the test output pulse allows

diagnosing external wiring faults as stuck with the power supply or short with the other safety input from the same M12 connector.

Note! Characteristics of the pulse test

 Pulse test length: 2ms  Pulse test period: 12ms

Note!

A pulse test can be configured to each safety Input of the M12 connector. It can be also associated to the both inputs.

 Power Supply – The test output is used as a power supply to supply 24 VDC for the safety input

device.

 Standard – The test output is used as a non-safe digital output.

Note!

No status led is associated to test outputs. Test output values and status can nevertheless be monitored via Inputs process image.

 Muting Lamp – The test output diagnoses whether the circuit and lamp are operational.

Warning!

When test outputs are configured for Power Supply or Muting Lamp, the use of double isolation cable could be required depending on the application and on the expected SIL/CAT to achieve.

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30  IP67 Safety Digital I/O Modules

When test output is activated, Muting Lamp feature controls the output current. Below 5mA, a fault is detected and the status is 0=OFF. Above 25mA is normal operation, the status is 1=ON.

Below is a typical scenario for muting lamp broken wire detection:

Test Output Process Value

Muting Lamp Physical State

Muting Lamp Status

Step #1: 1 = ON

Lamp good

Step #2: 1 = ON

Lamp broken

Step #3: 0 = OFF

Lamp broken

Step #4: 0 = OFF

Lamp replaced

Notes!

 Only Test Output 3 and Test Output 7 can be configured in Muting Lamp

mode.

 When Test Output is not activated, no broken wire fault can be detected.

However, once a default has been detected (step 2), the lamp replacement is diagnosed even if the Test Output is deactivated (step 3)

 Broken wire detection is performed at a 3 second period. Two

consecutive detections are required before the status is reported as BAD, so up to 6 seconds can be required before muting lamp status to be set to BAD

Typical wiring of safety inputs

M12 pining and wiring of the safety inputs with the associated pulse test outputs

 1: Test Output #1 (TP1, 24 VDC powered from UB)  2: Safe Input #1 (IN1)  3: Ground Logic/Input (UB GND)  4: Safe Input #0 (IN0)  5: Test Output #0 (TP0, 24 VDC powered from UB)

1 2

External Contact

TP0

IN0

IN1TP1

GND

External Contact

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Set Dual-channel Mode and Discrepancy Time

To support redundant channel safety devices, the consistency between signals on two input channels can be evaluated. This type of redundant wiring is called dual-channel mode.

Note!

 The dual-channel feature can only work by using the 2 safety input signals of the

same M12 port of the HarshIO.

 A total of six redundant channel safety devices can be connected to the HarshIO.

One redundant channel safety device per M12 port.

Either “Equivalent” or “Complementary” evaluation mode of the safety input pair has to be selected. In dualchannel mode, the HarshIO module monitors the time during which there is a discrepancy between the two channels.

Note!

Using the HarshIO SNCT software,

 The discrepancy time can be configured from 10ms to 30s, in increments of 10ms.  The discrepancy time default value is 10ms.

HarshIO behavior when used as equivalent dual safe inputs:

Safety Device

Physical State

Fault Detected

(*1)

Safe Input

Process Value

Safe Input

Process Status

Safe Input

Led Status

Input

(Pin 4)

Input+1

(Pin2)

Input

Input+1

Input

Input+1

Input

Input+1

Input

Input+1

0 = OFF

0 (safe)

0 (safe) 1 1

OFF

0 = OFF

1 = ON

0 (fault)

(a)

RED

(b)

RED

(b)

1 = ON

0 = OFF

0 (fault)

(a)

RED

(b)

RED

(b)

1 = ON

1 (active)

1 (active) 1 1

YELLOW

- - Yes

0 (fault)

0 (fault) 0 0

RED

BLINKING

RED

- - -

Yes

0 (fault)

0 (fault) 0 0

BLINKING

RED

(a): At “1” until discrepancy time expired. (b): OFF until discrepancy time expired.

HarshIO behavior when used as complementary dual safe inputs:

Safety Device

Physical State

Fault Detected

(1)

Safe Input

Process Value

Safe Input

Process Status

Safe Input

Led Status

Input

(Pin 4)

Input+1

(Pin2)

Input

Input+1

Input

Input+1

Input

Input+1

Input

Input+1

0 = OFF

0 (fault)

1 (fault)

(a)

RED

(b)

RED

(b)

0 = OFF

1 = ON

0 (safe)

1 (safe) 1 1

OFF

YELLOW

1 = ON

0 = OFF

1 (active)

0 (active) 1 1

YELLOW

OFF

1 = ON

0 (fault)

1 (fault)

(a)

RED

(b)

RED

(b)

- - Yes

0 (fault)

1 (fault) 0 0

RED

BLINKING

RED

- - -

Yes

0 (fault)

1 (fault) 0 0

BLINKING

RED

(a): At “1” until discrepancy time expired. (b): OFF until discrepancy time expired.

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32  IP67 Safety Digital I/O Modules

Notes!

 (1) When dual channel inputs are configured as “Standard” or “Safety”, only internal

hardware faults and discrepancy between inputs can be detected. Inputs shall be configured as “Safety Pulse Test” to allow external short to 1 detection

 At inputs transition, during the discrepancy time, inputs are reported at the safe

state

Safety Input Fault Recovery

Note!

If a fault is detected, the safety input (or safety inputs) process value remains in the safety state until the following procedure is applied:

1. Removed the cause of the fault.

2. Set the safety input to his safety state.

Input Delay

On-delay and Off-delay can be configured individually for each input.

On-delay The On-delay is the minimum time necessary for a physical input switched to ON to be reported as “1” on the

network. For example, if the On-delay is set to 5ms, the Input will be reported on the network at level “1”, after the Input has been evaluated at ON during at least 5ms.

Off-delay The Off-delay is the minimum time necessary for a physical input switched to OFF to be reported as “0” on the

network. For example, if the Off-delay is set to 5ms, the Input will be reported on the network at level “0”, after the Input has been evaluated at OFF during at least 5ms.

Note!

Using the HarshIO SNCT software,  On-delay and Off-delay parameters can be configured from 0 to 1000ms, in

increments of 1ms.

 On-delay and Off-delay default values are 0.

Input Error Latch Time

The Input Error Latch Time is a unique parameter that applies for all the Inputs.

The purpose for latching input errors is to make sure that intermittent faults that can only exist for a few milliseconds are latched long enough to be read by the controller. It defines the minimal duration a detected fault on any safe inputs shall be reported on the network in order to able the controller to detect it.

Note!

Using the HarshIO SNCT software,  Input Error Latch Time default parameters can be configured from 0 to 65530ms, in

increments of 10ms.

 Input Error Latch Time default value is 1000ms.  The amount of time to latch the error must be based on the RPI of the safety

connection, the application safety task watchdog, and other application specific variables.

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Safety Sourcing Outputs (TCDEC-8B4P-D1U-Gx and TCDEC-8B4P-DYU-Gx)

Safety sourcing outputs are used to drive the state of output devices.

Note!

HarshIO safe outputs are:

 current sourcing at max. 1A  short circuit protected  pulse test configurable

A Safety Output can be configured as:

 Not Used (default) - The output is disable and doesn’t participate in any safety function.  Safety Pulse Test - The output generates pulse tests (when the output is active) to monitor short-

circuit between output pin and power supply (stuck at “1”), or short with other active output from the same M12 connector.

Notes! Using the HarshIO SNCT software,

 The Pulse tests length is configurable from 300µs to 10ms, in increments

of 100µs.

 Pulse tests length default value is 500µs  Pulse tests period: 468ms

 In addition to external shorts detection, all safety functions involved in

outputs switch-off are also diagnosed at each period. So a series of 4 pulse tests are applied on each safety output.

Note!

The pulse test should be configured according to the impedance of the connected device. HarshIO safety has been design to control a wide range of device by using an active discharge circuit. For each pulse test higher than 500µs (or equal), if a residual voltage is present, a 50mA current is clamped during 300µs. Nevertheless, if it is not enough and output goes into safe state due to the capacitive load of the connected equipment, the pulse length can be increased (up to 10ms).

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Notes!

 Safety Sourcing outputs should not be used to provide power to a device

or sub-system whom the resistive and capacitive load could vary during operation.

Warning!

Be careful of the response time of the output device to prevent any malfunction because of pulse test.

 Safety No Pulse Test - The output is used without pulse test.

Note!

In this mode, diagnostics are done on the output. When a sourcing output is switched off, the measured state can be different to the expected one due to the capacitive load of the connected equipment. HarshIO have been design to control a wide range of equipment by using an active discharge circuit. When a sourcing output is switched off, if a residual voltage is present, a 50mA current is clamped during 2ms.

M12 pining and wiring of the safety sourcing outputs:

 1: 24 VDC (powered from UL)  2: Safe Output #1 (OUT1)  3: Ground Output (UL GND)  4: Safe Output #0 (OUT0)  5: Ground Output (UL GND)

Note!

The maximum current available on the Pins #1 (24 VDC) of the 2 Output sourcing ports is 3.5A.

1 2

External Load

OUT0

OUT1

GND

External Load

GND

24V

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Using Safety Sourcing Outputs in Single-Channel Outputs

Outputs from the same M12 connector are configured as 2 single channel outputs.

When activated by the logic controller, output is turned ON and status is “1” (good) as long as no fault is detected. On fault detection, Output is forced to safe state OFF and status is set to “0” (bad).

HarshIO behavior when used as single safe outputs:

Safe Output

Process Value

Fault Detected

Safety Device

Physical State

Safe Output

Process Status

Safe Output

Led Status

0 = OFF (safe)

OFF

1 = ON (active)

YELLOW

Yes

(on output itself)

0 = OFF (fault)

RED

Yes

(on the partner)

0 = OFF (fault)

BLINKING RED

Note!

When a fault is detected on a single channel output, both outputs on the same M12 connector will switch to safe state.

Note!

 When no pulse test is configured on a safety output, only read back value is used to

detect fault, so only short to 1 when output is driven to 0 and short to 0 when output is driven to 1 are detected

 When pulse tests are activated, internal faults as well as short to 1 can be then

detected

Using Safety Outputs as Dual-Channel outputs

Outputs from the same M12 connector can be configured as an output pair.

When both output process values are activated by the logic controller, the dual outputs are turned ON and

status is “1” (good) as long as no fault is detected. On hardware fault detection or discrepancy of output

process values, outputs are forced to safe state OFF and status is set to “0” (bad).

HarshIO behavior when used as dual safe outputs:

Safe Output

Process Value

Fault Detected

Safety Device

Physical State

Safe Output

Process Status

Safe Output

Led Status

Output

Output+1

Output

Output+1

Output

(Pin 4)

Output+1

(Pin2)

Output

Output+1

Output

Output+1

0 = OFF (safe)

1 1 OFF

OFF

0 = OFF (fault)

0 0 RED

RED

0 = OFF (fault)

0 0 RED

RED 1 1

1 = ON (active)

YELLOW

- - Yes

0 = OFF (fault)

0 0 RED

BLINKING

RED

- - -

Yes

0 = OFF (fault)

BLINKING

RED

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Safety Output Fault Recovery

Note!

If a fault is detected, the safety output (or safety outputs) physical value remains in the safety state until the following procedure is applied:

 Removed the cause of the fault.  Set the safety output to his safety state.

Output Error Latch Time

The Output Error Latch Time is a unique parameter that applies for all the Outputs.

The purpose for latching output errors is to make sure that intermittent faults that can only exist for a few milliseconds are latched long enough to be read by the controller. It defines the minimal duration a detected fault on any safety outputs shall be reported on the network in order to able the controller to detect it.

Note!

Using the HarshIO SNCT software,  Output Error Latch Time default parameters can be configured from 0 to 65530ms,

in increments of 10ms.

 Output Error Latch Time default value is 1000ms.  The amount of time to latch the error must be based on the RPI of the safety

connection, the application safety task watchdog, and other application specific variables.

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Bipolar Safety Outputs (TCDEC-8B4B-D1U-Gx and TCDEC-8B4B-DYU-Gx)

Bipolar safety outputs are used to drive the state of output devices. The bipolar outputs combines the safety sourcing output and the safety sinking output of the same M12

connector as a output pair in dual channel mode and can support current up to 2A.

Note!

HarshIO bipolar safety outputs are:

 current sourcing at max. 2A.  always configured in dual-channel mode meaning that a maximum of two safety

output devices can be connected to a HarshIO module.

 short circuit protected

A bipolar Safety Output can be configured as:

 Not Used (default) - The bipolar outputs are disable and don’t participate in any safety function.

 Safety Pulse Test - The output sourcing generates a pulse test (when the output is active) to monitor

short-circuit between output sourcing signal and power supply (stuck at “1”). The output sinking generates a pulse test (when the output is active) to monitor short-circuit between output sinking signal and ground (stuck at “0”).

Note! Using the HarshIO SNCT software,

 Each safety bipolar output pair can be configured individually with or

without pulse test.

 The Pulse test length is configurable from 300µs to 10ms, in increments

of 100µs, with a default value of 700µs. In the case of bipolar outputs, pulse management has been designed in order that the default value should work in almost applications, including applications where the resistive and capacitive load of the connected device or sub-system can vary during operation. It is then strongly recommended to keep default value unchanged. Changing this parameter should be done only if an issue is observed during application testing.

 Pulse test period: 468ms

In addition to external shorts detection, all safety functions involved in outputs switch-off are also diagnosed at each period. So a series of 4 pulse tests are applied on each safety output.

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Note!

The pulse test should be configured according to the impedance of the connected device. HarshIO safety bipolar output has been design to control a wide range of device by using an active discharge circuit. For each pulse test higher than 700µs (or equal), if a residual voltage is present, a 50mA current is clamped during 500µs. Nevertheless, if it is not enough and output goes into safe state due to the capacitive load of the connected equipment, the pulse length can be increased (up to 10ms).

 Safety No Pulse Test - The bipolar output is used without a pulse test.

M12 pining and wiring of the safety bipolar outputs:

 1: 24 VDC (powered from UL)  2: Safety Output #1 (OUT1 - Sinking)  3: Ground Output (UL GND)  4: Safety Output #0 (OUT0 - Sourcing)  5: Ground Output (UL GND)

Note!

The maximum current available on the Pins #1 (24 VDC) of the 2 Output bipolar ports is

3.5A.

Danger!

Load(s) shall never be connected between Pin 4 (sourcing output) and GND as well as between Pin 2 (sinking output) and 24 V.

24 V and GND pins shall only be used to provide power to external device but shall never been wired in association with a safety output.

Note!

A frequent use of bipolar safety outputs is to power and Molex non-safe HarshIO modules from the bipolar M12 connector.

A special M12 – Mini change cable can be ordered for easy wiring. In this case:

 UB (logic and Input) of the non safe module are powered by the 24 V (pin 1) of

the bipolar connector.

 UL (Output) of the non-safe module is directly switched on/switched off by the

bipolar pair (pin 2 and 4).

1 2

OUT0

OUT1

GND

External Load

24V GND

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I/O Status

HarshIO safety module provides status information to monitor the I/O circuit. The status information can be read by the EtherNet/IP scanner.

Note!

When a fault is detected, the status value is “0” meaning bad. On normal operation, the status value is “1” meaning good.

Each individual point listed below has its own individual status:

 Safety Input Status  Test Output Status  Safety Output Status (sourcing or bipolar)

Behavior in case of fault

Detected fault

Fail safe state applied on

Method to recover

Fieldbus communication availability

Safety Input pulse test failure

(single channel)

Faulted safe input

1. Remove the fault

2. Switch input in the safe state

Yes

Wait latch error time expired

Safety Input pulse test failure

(dual channel)

Safety inputs pair

1. Remove the fault

2. Switch input in the safe state

Yes

Wait latch error time expired

Safety input pair discrepancy

(dual channel)

Safety inputs pair

1. Remove the fault

2. Switch input in the safe state

Yes

Wait latch error time expired

Safety output pulse test failure or read back value error

(single channel)

Both single safety outputs on same connector

1. Remove the fault

2. Switch outputs in the safe state

Yes

Wait latch error time expired

Safety output pulse test failure or read back value error

(dual channel)

Safety output pair

1. Remove the fault

2. Switch outputs in the safe state

Yes

Wait latch error time expired

Safety output discrepancy error

(dual channel)

Safety Output pair

1. Remove the fault

2. Switch outputs in the safe state

Yes

Wait latch error time expired

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40  IP67 Safety Digital I/O Modules

Overvoltage/under voltage error on input power (UB)

Whole module (all safety inputs and outputs)

Power cycle needed

Yes

Overvoltage error on output power (UL)

Whole module (all safety inputs and outputs)

Power cycle needed

Yes

Under voltage error on output power (UL)

All Safety outputs

1. Remove the fault

2. Switch outputs in the safe state

Yes

Overcurrent on input power (UB)

Whole module (all safety inputs and outputs)

Power cycle needed

Yes

Overcurrent on output power (UL)

Whole module (all safety outputs)

Power cycle needed

Yes

Temperature error

Whole module (all safety inputs and outputs)

Power cycle needed

NO  Critical Error

All I/O leds blinked

Internal hardware error (CPU, RAM, ADC 3,3V,…)

Whole module (all safety inputs and outputs)

Power cycle needed

NO  Critical Error

All I/O leds blinked

CIP Safety communication error (input connection)

All safety inputs

Originator to restart connection

Yes

CIP Safety communication error (output connection)

All safety outputs

Originator to restart connection

Yes

Rotary Change Value

Whole module (all safety inputs and outputs)

Power cycle needed

Yes

Remove External Key

Whole module (all safety inputs and outputs)

Power cycle needed

Yes

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41  IP67 Safety Digital I/O Modules

Response Time

Calculate the response time

In order to calculate the response time of a safety function, the worst-case response times of all components involved must be added to the delays on the communication paths. Below are the response times of the HarshIO safety modules to perform these calculations.

Warning!

The safety function is not guaranteed if the following response times are calculated incorrectly.

1. Maximum response time of a digital safety input (single and dual-channel modes)

Calculate the maximum response time of a safety Input in error-free state. The response time is calculated from the instant of the physical event happened to a connected sensor and the emission of the corresponding telegram on the EtherNet/IP network by the HarshIO safety module.

Calculation Delay Times Response time of the connected sensor/switch + _______ ms HarshIO Input delay configured + 500μs tolerance + _______.5 ms Internal maximum processing time of HarshIO module PTIN max + 10.5 ms

---------------------------Maximum response time of a digital safety input = _______ ms

2. Maximum response time of a digital safety output (single and dual-channel modes)

Calculate the maximum response time of a safety output in error-free state. The response time is calculated from the moment a telegram is received by the HarshIO safety module and the actuator physical processes the switch-off physical event.

Calculation Delay Times Internal maximum processing time of HarshIO module PTOUT max: + 4.5 ms HarshIO pulse test configured + _______ ms Switch-off time of connected actuator/relay + _______ ms Additional Switch-off delay (physical signal time commutation) + _______ ms

---------------------------Maximum response time of a digital safety output = _______ ms

Note!

The maximum response type of a detected safety error is 10ms (emission of the corresponding telegram on the EtherNet/IP network by the HarshIO safety module).

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42  IP67 Safety Digital I/O Modules

5. Product Characteristics

Hardware characteristics

Type

12x Safe Inputs + 4x Safe Outputs

12x Safe Inputs + 2x Bipolar Safe Outputs

Product Reference

TCDEC-8B4P-DYU-G TCDEC-8B4P-D1U-G

TCDEC-8B4B-DYU-G TCDEC-8B4B-D1U-G

Safety

SIL (per IEC 61508 / IEC 62061)

Up to SIL3 (when configured in dual I/O Channel)

CAT (per ISO 13849-1)

Up to Cat. 4 (when configured in dual I/O Channel)

PL (per ISO 13849-1)

Up to PL e (when configured in dual I/O Channel)

PFH

9.70E-11

9.02E-11

PFDavg

8.47E-06

7.88E-06

DCavg

98.66%

98.58%

MTTF

679 years

851 years

Service Life

20 Years

Power

Power IN connector

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

Power OUT connector

Mini Change (7/8”), 4-pin or 5-pin, female, stainless steel, shielded, Maximum 8 A

Module & Input power (UB)

24 VDC, -15% / +20% (protected against power crossing).

Operating current (UB)

<100 mA

Output power (UL)

24 VDC, -15% / +20% (protected against power crossing)

Operating current (UL)

<20 mA (without load)

Safe Inputs

Channels

12 channels

Connector

M12 Ultra-Lock, 5-pin, female, A-Coded, stainless steel, unshielded

(*)

Input type

IEC61131-2 type 3

Input voltage

On / Off delay

Configurable from 0 to 1000ms (0 by default)

Warning!

If UB is over 36 V for a period of 2 seconds or more. The safety module will go in fail state (all LEDs are blinking in red) and considered as destroyed. Indeed, the internal surge protections are irreversibly damaged and therefore the module cannot operate anymore.

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Pulse Test Output

Test rate interval

Max. 12ms

Pulse test length

2ms

Sensor power supply

0.7A

Max short circuit current

2A at 25°

Safe Outputs

Output type

Sourcing (PNP)

Bipolar

Channels

4 channels, 2-wires

2 channels, 2-wires

Output voltage

Connector

M12 Ultra-Lock, 5-pin, female, A-Coded, stainless steel

Test rate interval

Max. 2s

Rated Output current

1A per channel

2A per channel

Maximum Short circuit current

(transitory before safety switch-off)

6.5 A

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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44  IP67 Safety Digital I/O Modules

Fieldbus

Ethernet connectors

M12, 4-pin, female, D-Coded, stainless steel, shielded

IP setting

DHCP based on MAC (infinite lease), DHCP based on Name, Static IP

Protocol

CIP Safety EtherNet/IP Adapter according specification Vol 5-2.6 (CIP Safety) and Vol 2 – 1.18 (EtherNet/IP)

Data access

Implicit messages for I/O data transfer

Implicit (I/O) connection

 1x Exclusive Owner (EO) connection (safe information)  1x Input Only (IO) connection (to share safe process data with a non-safe scanner)  Up to 7 Listen Only (LO) (to share safe process data with a non-safe scanner)

Explicit (EM) connection

 Up to 8 connections

CIP safety connection

Type 1 and Type 2

Supported CIP Objects

 0x01 – Identity object  0x02 – Message Router object  0x04 – Assembly object

o Safety Input Profiles

 0x20C (TO)  0x21C (TO)  0x22C (TO)  0x243 (TO)  0x25C (TO)  0x27C (TO)

o Safety Input Vendor Specific

 0x300 (TO)

o Safety Output Profiles

 0x233 (OT)

o Safety Output Vendor Specific

 0x301 (OT)

o Configuration

 0x302 (TO)

 0x06 – Connection Manager object  0x23 – Safety discrete IO Profile  0x37 – File Object  0x3B – SDOP object  0x3D – SDIP object  0x3F – SDCO object  0x47 – DLR object  0x48 – QoS (Quality of Service)  0x80 – SDCI object  0xF5 – TCP/IP Interface object  0xF6 – Ethernet Link object

Integrated Switch

 2x ports integrated switch  Speed: 100Mbps  Auto negotiation  Auto crossing  Auto polarity  1x status Led per port  Storm Protection against network loop (Broadcast, Multicast and Unicast packets)

Request Packet Interval (RPI)

For safety Inputs (configurable per Scanner connection)  ≥10ms minimum For safety Outputs (single Scanner connection)  ≥10ms minimum

IP Address Conflict Detection

Yes (ACD supported)

DLR

Yes (beacon node)

ODVA conformance

Yes

Default Ethernet setting:

 IP address: DHCP  Subnet mask: DHCP  Gateway: DHCP  ETH1 port: Auto negotiation + Auto-MDI  ETH2 port: Auto negotiation + Auto-MDI  ACD Enabled

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45  IP67 Safety Digital I/O Modules

Mechanical

Housing dimension

235 x 60 x 44 mm (9.25"x2.36x1.73")

Housing material

PBT VALOX 420 SEO RED 7701

Flammability Standard

UL 94 V-0

Corner mounting hole

4 mounting holes, 5 x10 mm

Ground stud

Yes, stainless steel (allows the continuity of the ground when the module is mounted on the chassis machine)

Memory Key

Internal window key or M8 key

Operating temperature

-25°c … +70°c

Storage temperature

-40°c … +90°c

Installation Altitude

Max. 2000m

Vibration resistance

Operating: 7mm p-p (5-15.7Hz), 7g (15,7Hz to 500Hz), 3 axis

Shock resistance

Operating: 15g, 11ms, 3 axis Non-operating: 50g, 6ms, 3 axis

Relative humidity

10 % to 95 %, non-condensing

Protection Class

IP67

MTBF

523 750 hours / 59,8 years at 25°C 345 000 hours / 39.4 years at 40°C 136 000 hours / 15.5 years at 70°C

Note!

7/8” accessories (cordsets, plugs …) connected to the module power connectors shall be screw with a torque of 2.0Nm to ensure a correct sealing to achieve IP67 rating.

M12 accessories (cordsets, plugs …) connected to the module I/O and network connectors shall be screw with a torque of 2.0Nm to ensure a correct sealing to achieve IP67 rating.

M8 accessories (memory key, plugs …) …) connected to the module I/O and network

connectors shall be screw with a torque of 2.0Nm to ensure a correct sealing to achieve IP67 rating.

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46  IP67 Safety Digital I/O Modules

EMC

Standard

Comment

Emitted interference

EN 61000-6-4

Class A (Industrial area)

Noise immunity zone B

EN 61000-6-2

Industrial area

EN 61000-4-2

ESD 8kV air discharge 6kV contact discharge

EN 61000-4-3

High-frequency electromagnetic field 80MHz … 1000MHz, 20V/m, 80% AM (1kHz)

1.4GHz ... 2.0GHz, 6V/m, 80% AM (1kHz) 2GHz ... 2.7GHz, 2V/m, 80% AM (1kHz)

EN 61000-4-6

Conducted disturbances, induced by radio 150kHz … 80MHz, 10V, 80% AM (1kHz)

EN 61000-4-4

Burst +/- 3kV 5/50 ns, 5 kHz on power ports +/- 2kV 5/50 ns, 5 kHz on I/O ports +/- 2kV 5/50 ns, 5 kHz communication ports

EN 61000-4-5

Surge 1kV line to line, 2kV line to earth on power ports 2kV line to line on I/O ports 2kV line to earth on communication ports

Warning!

Molex devices comply with EU directives and conform (DoC) to the related EMC standards so that they can be easily integrated into other devices or machines. However, EMC compliance of the whole system remains under system builder responsibility.

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47  IP67 Safety Digital I/O Modules

Mechanical characteristics

Size and dimensions (in mm)

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48  IP67 Safety Digital I/O Modules

Physical I/O mapping

4-pin power connector

5-pin power connector

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49  IP67 Safety Digital I/O Modules

Safety I/O assemblies

The I/O process data are available through the EtherNet/IP assemblies which depend on the required data:

 Safety Input Process Data

o Safety Discrete Input Profiles

 Assembly 524 (20C Hex)  Assembly 540 (21C Hex)  Assembly 556 (22C Hex)  Assembly 579 (243 Hex)  Assembly 604 (25C Hex)  Assembly 636 (27C Hex)

o Vendor Specific

 Assembly 768 (300 Hex):

 Safety Output Process Data

o Safety Discrete Output Profile

 Assembly 563 (233 Hex)

o Vendor Specific

 Assembly 769 (301 Hex)

 Configuration Data

o Vendor Specific

 Assembly 770 (302 Hex)

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50  IP67 Safety Digital I/O Modules

Safety I/O connections

The I/O module supports

 1x Exclusive Owner (EO) connection for controlling safe Input/Output process data.  1x Input Only (IO) connection for reading safe Input/Output process data with a safe or non-safe

EtherNet/IP scanner.

 Up to 7 Listen Only (LO) (to read safe process data with a non-safe EtherNet/IP scanner).

Exclusive owner

This connection is bi-directional: the originator (safety PLC) produces data consumed by the target (HarshIO safety) and the target produces data that is consumed by the originator. This connection type is called an Exclusive Owner (EO) connection or the controlling connection.

The Exclusive Owner (EO) connection is used to control the safe Input and safe Output process data. No more than one I/O EO connection can be an Input/Output connection.

Input Only

For this connection type, only the target (HarshIO safety) produces data, which is consumed by the originator (safety PLC). The originator will only send a heartbeat packet, sometimes at a reduced interval (less frequently than the RPI) used to allow the HarshIO safety to identify when the connection is broken. This input only connection can be either unicast, either multicast.

Note!

Upload EDS file from the safety module to easily configure the connection.

Input Assembly 768 (300 Hex), Size 13 bytes Output Assembly (Heartbeat) 198 (C6 Hex), Size 0 bytes Configuration Assembly 103 (67 Hex), size 0 byte

Listen Only

This connection type is identical to an Input Only connection type, with a single exception: a Listen Only connection can only exist when one of the other I/O connection (EO) types has been established. That is, a

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51  IP67 Safety Digital I/O Modules

Listen Only connection cannot be established until an Input/Output or Input Only connection has been established, and conversely when the last non-Listen-Only connection has been closed or has timed out, the Listen Only connection will automatically close as well. This connection type is the least-frequently used type.

Note!

Upload EDS file from the safety module to easily configure the connection.

Input Assembly 768 (300 Hex), Size 13 bytes Output Assembly (Heartbeat) 199 (C7 Hex), Size 0 bytes Configuration Assembly 103 (67 Hex), size 0 byte

Example of Architecture – EtherNet/IP safety and non-safe scanners sharing process data.

ETHERNET SWITCH

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

Safety Controller

Non-Safe Controller

HarshIO Safety

1x safe Exclusive Owner connection

Safe I/O

Non-safe I/O

1x non-safe Input Only connection

Robot

Controller

HMI

Up to 7x non-safe Listen Only connections

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52  IP67 Safety Digital I/O Modules

Safety I/O data mapping

Safe Inputs assemblies

Safety Discrete Input Profiles

Byte

Offset

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Input Data (Assembly 524 - 20C Hex), Size: 2 byte(s)

Safety Inputs

n/u

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

n/u: Not used Safety Input Ix: Safety Input process value on channel Ix

Byte

Offset

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Input Data (Assembly 540 – 21C Hex), Size: 2 byte(s)

Safety Inputs +

Global Safety Input

Status

Global

Safety

Input

Status

CIS

n/u

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

n/u: Not used

Safety Input Ix: Safety Input process value on channel Ix Combined Safety Input Status CIS: Set to “0” when an error is detected on any of the safety inputs.

Byte

Offset

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Input Data (Assembly 556 - 22C Hex), Size: 3 byte(s)

Safety Inputs

Safety Input Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

n/u: Not used

Safety Input Ix: Safety Input process value on channel Ix Safety Input Status Ix: Set to “0” when an error is detected on safety input Ix

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53  IP67 Safety Digital I/O Modules

Byte

Offset

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Input Data (Assembly 579 - 243 Hex), Size: 1 byte(s)

Safety Output Status

n/u

Safety

Output

Status

Safety

Output

Status

Safety

Output

Status

Safety

Output

Status

n/u: not used Safety Output Status Ox: Set to “0” when an error is detected on safety output Ox

Byte

Offset

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Input Data (Assembly 604 - 25C Hex), Size: 2 byte(s)

Safety Inputs +

Global Safety

Input Status +

Global Safety

Output Status

Global

Safety

Input

Status

CIS

Global

Safety

Output

Status

COS

n/u

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

n/u: not used

Safety Input Ix: Safety Input process value on channel Ix Combined Safety Input Status CIS: Set to “0” when an error is detected on any of the safety inputs Combined Safety Output Status COS: Set to “0” when an error is detected on any of the safety outputs

Byte

Offset

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Input Data (Assembly 636 - 27C Hex), Size: 3 byte(s)

Safety Inputs +

Global Safety

Input Status

Global

Safety

Input

Status

CIS

n/u

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety Output Status

n/u

Safety

Output

Status

Safety

Output

Status

Safety

Output

Status

Safety

Output

Status

n/u: not used

Safety Input Ix: Safety Input process value on channel Ix Combined Safety Input Status CIS: Set to “0” when an error is detected on any of the safety inputs Safety Output Status Ox: Set to “0” when an error is detected on safety output Ox

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54  IP67 Safety Digital I/O Modules

Vendor Specific

Byte

Offset

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Input Data (Assembly 768 - 300 Hex), Size: 13 byte(s)

Safety Inputs

n/u

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input

Safety

Input Status

n/u

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Safety

Input

Status

Test Output

Value

n/u

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test Output

Status

n/u

Test

Output

Status

TOS

Test

Output

Status

TOS

Test

Output

Status

TOS

Test

Output

Status

TOS

Test

Output

Status

TOS

Test

Output

Status

TOS

Test

Output

Status

TOS

Test

Output

Status

TOS

Test

Output

Status

TOS

Test

Output

Status

TOS

Test

Output

Status

TOS

Test

Output

Status

TOS

Safety Output

Monitoring

n/u

Safety Output Monito

ring

Safety Output Monito

ring

Safety Output Monito

ring

Safety Output Monito

ring

Safety Output

Status

n/u

Safety Output

Status

Safety Output

Status

Safety Output

Status

Safety Output

Status

Miscellaneous

Input

Over

Current

Error

Output

Over

Current

Error

Muting

Lamp

Status

Muting

Lamp

Status

Global

Safety

Input

Status

CIS

Global

Safety Output

Status

COS

Input

Power

Error

Output

Power

Error

n/u: not used

Safety Input Ix: Safety Input process value on channel Ix Test Output TOx: Safety process value on channel Test Output TOx Safety Output Monitoring Ox: Safety Output process value on channel Ox for PLC monitoring.

Safety Input Status Ix: Set to “0” when an error is detected on safety input Ix Test Output Status TOSx: Set to “0” when an error is detected on the Test Output TOx Safety Output Status Ox: Set to “0” when an error is detected on safety output Ox

Combined Safety Input Status CIS: Set to “0” when an error is detected on any of the safety inputs Combined Safety Output Status COS: Set to “0” when an error is detected on any of the safety outputs Muting Lamp Status TOx: Set to “0” when an muting lamp broken wire error is detected on channel x

Output Power Error UB: Diagnostic bit for Output power supply (UL)

 Set to “1”, if UL is out of valid range  Set to “0”, if UL is within valid range

Input Power Error UL: Diagnostic bit for Logic/Input power supply (UB)

 Set to “1”, if UL is out of valid range  Set to “0”, if UL is within valid range

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55  IP67 Safety Digital I/O Modules

Note!

Safety inputs configured as “not used” will report a process value of 0 and a safety

status of 1.

Safety Outputs

Safety Discrete Output Profile

Byte

Offset

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Output Data (Assembly 563 - 233 Hex), Size: 1 byte(s)

Safety Outputs

n/u

Safety Output

n/u: not used

Safety Output Ox: Safety Output process value on channel x

Vendor Specific

Byte

Offset

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Output Data (Assembly 769 - 301 Hex), Size: 4 byte(s)

Safety Outputs

n/u

Safety Output

Test Outputs

n/u

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

Test

Output

n/u: not used

Safety Output Ox: Safety Output process control value on channel x Test Output TOx: Test Output process control value on channel x

Notes!

Values provided for Safety outputs are ignored if corresponding outputs are configured as “not used”

Values provided for Test Outputs are ignored if corresponding Test Outputs are not configured as a “Standard Output”

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56  IP67 Safety Digital I/O Modules

Configuration Data

Note!

The data size can be set to “0” if the EtherNet/IP CIP Safety Scanner doesn’t need to send configuration data at the establishment of the connection (Safety Forward Open request), which is the case for example for Rockwell Safety controllers.

Note!

The description of the configuration data in the below table are for information purpose only. In fact, the configuration data are managed and sent directly by Molex SNCT software.

Vendor Specific

Byte

Offset

Bit 15

Bit 14

Bit 13

Bit 12

Bit 11

Bit 10

Bit 9

Bit 8

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Configuration (Assembly 770 - 302 Hex), Size: 123 bytes

Version

Minor Version

Major version

Test Output Mode

Test Output O1

Test Output O0

Test Output O3

Test Output O2

Test Output O5

Test Output O4

Test Output O7

Test Output O6

Test Output O9

Test Output O8

Test Output O11

Test Output O10

Output Error

Latch Time

Output Error Latch Time

Output Mode & Pulse

test Length

Pulse test Length O0

Output Mode O0

Pulse test Length O1

Output Mode O1

Pulse test Length O2

Output Mode O2

Pulse test Length O3

Output Mode O3

Dual Safe Output

Mode

Dual Output Mode O3 / O2

Dual Output Mode O0 / O1

Input Error Latch Time

Parameters – Input I0

OFF  ON Delay Input I0

ON  OFF Delay Input I0

Test Source Input I0

Input Mode I0

Parameters – Input I1

OFF  ON Delay Input I1

ON  OFF Delay Input I1

Test Source Input I1

Input Mode I1

Parameters – Input I2

OFF  ON Delay Input I2

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57  IP67 Safety Digital I/O Modules

ON  OFF Delay Input I2

Test Source Input I2

Input Mode I2

Parameters – Input I3

OFF  ON Delay Input I3

ON  OFF Delay Input I3

Test Source Input I3

Input Mode I3

Parameters – Input I4

OFF  ON Delay Input I4

ON  OFF Delay Input I4

Test Source Input I4

Input Mode I4

Parameters – Input I5

OFF  ON Delay Input I5

ON  OFF Delay Input I5

Test Source Input I5

Input Mode I5

Parameters – Input I6

OFF  ON Delay Input I6

ON  OFF Delay Input I6

Test Source Input I6

Input Mode I6

Parameters – Input I7

OFF  ON Delay Input I7

ON  OFF Delay Input I7

Test Source Input I7

Input Mode I7

Parameters – Input I8

OFF  ON Delay Input I8

ON  OFF Delay Input I8

Test Source Input I8

Input Mode I8

Parameters – Input I9

OFF  ON Delay Input I9

ON  OFF Delay Input I9

Test Source Input I9

Input Mode I9

Parameters – Input

I10

OFF  ON Delay Input I10

ON  OFF Delay Input I10

Test Source Input I10

Input Mode I10

Parameters – Input

I11

OFF  ON Delay Input I11

ON  OFF Delay Input I11

Test Source Input I11

Input Mode I11

Dual Safe Mode

100

n/u

Dual Safe Input Mode I1 / I0

Dual Safe

Discrepancy Time

102

Discrepancy Operation Input I1 / I0

Dual Safe Mode

104

n/u

Dual Safe Input Mode I3 / I2

Dual Safe

Discrepancy Time

106

Discrepancy Operation Input I3 / I2

Dual Safe Mode

108

n/u

Dual Safe Input Mode I5 / I4

Dual Safe

Discrepancy Time

110

Discrepancy Operation Input I5 / I4

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Dual Safe Mode

112

n/u

Dual Safe Input Mode I7 / I6

Dual Safe

Discrepancy Time

114

Discrepancy Operation Input I7 / I6

Dual Safe Mode

116

n/u

Dual Safe Input Mode I9 / I8

Dual Safe

Discrepancy Time

118

Discrepancy Operation Input I9 / I8

Dual Safe Mode

120

n/u

Dual Safe Input Mode I11 / I10

Dual Safe

Discrepancy Time

122

Discrepancy Operation Input I11 / I10

Major Version: 1 Minor Version: 1

Test Output Mode

• 0: Not Used

• 1: Standard

• 2: Pulse Test

• 3: Power Supply

• 4: Muting Lamp (only possible for Input 3 and Input 7)

Output Error Latch Time (in ms)

A value between 0 and 65530; shall be a multiple of 10.

Output Mode

• 0: Not Used

• 1: Safety

• 2: Safety Pulse Test

Output Pulse test Length (in ms)

A value between 3 and 100; for bipolar odd output, Pulse test Length is always 0.

Dual Safe Output Ox/Ox+1 Mode

• 0: Single (Not available for bipolar)

• 1: Dual

Input Error Latch Time (in ms)

A value between 0 and 65530; shall be a multiple of 10.

Input Ix Off  On Delay (in ms)

A value is between 0 and 1000.

Input Ix On  Off Delay (in ms)

A value is between 0 and 1000.

Input Ix Mode

• 0: Not Used

• 1: Safety Pulse Test

• 2: Safety

• 3: Standard

Input Ix Test Source (only test output on same connector can be used in this list):

• 0: Not Used

• 1: Test Output 0

• 2: Test Output 1

• 3: Test Output 2

• 4: Test Output 3

• 5: Test Output 4

• 6: Test Output 5

• 7: Test Output 6

• 8: Test Output 7

• 9: Test Output 8

• 10: Test Output 9

• 11: Test Output 10

• 12: Test Output 11

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Input Ix/Ix+1 Dual Safe Mode

• 0: Single

• 1: Equivalent

• 2: Complementary

Dual Safe Input Ix / Ix+1 Discrepancy Time (in ms)

A value between 10 and 30000; shall be a multiple of 10.

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Pin assignment

4-pin power supply versions

Note!

The shell of the 8x M12 I/O connectors is not connected to earth. If required, You should splice the cable at each end for grounding it.

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5-pin power supply versions

Note!

The shell of the 8x M12 I/O connectors is not connected to earth. If required, You should splice the cable at each end for grounding it.

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LED assignment

LED positions

Warning: LEDs are NOT reliable indicators and cannot be guaranteed to provide accurate information. They should ONLY be used for general diagnostics during commissioning or troubleshooting. Do not attempt to use LEDs as operational indicators

Outputs Aux. Power LED (UL)

Note: The outputs of the module operate only if the LED is ON

12x Safety Input Status LED

2x Ethernet Link Status LED

Module & Inputs Power LED (UB)

Network Status LED

In-coming Bus Power Connector (Ui)

Use this connector to power the module.

Out-coming Bus Power Connector (Uo)

Use this connector to daisy-chain the power to an additional HarshIO eIP module

8x Plastic labels

Available to write user information

Shield Plate

For protective grounding

Module Status LED

Safety Configuration Lock LED

4x Safety Output Status LED

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LED assignment

Module Logic and Input Power Status LED (UB)

LED State

Description OFF

Module power supply not connected

GREEN

Module power supply is connected and in is the valid range (24 VDC  -20% to +25%)

YELLOW

Module power supply is detected but is outside the valid range (24 VDC  -20% to +25%)

Module Output Auxiliary Power Status LED (UL)

LED State

Description OFF

Module power supply not connected

GREEN

Module power supply is connected and in is the valid range (24 VDC  -20% to +25%)

YELLOW

Module power supply is detected but is outside the valid range (24 VDC  -20% to +25%)

Safe Input Status LEDs (Ix)

LED State

Safety Input Status

Description OFF

Good

Input is OFF or module being configured.

YELLOW

Good

Input is ON

RED

Fault

A fault in the input circuit has been detected, or a discrepancy error between the two Inputs of a dual input pair has been detected.

BLINKING RED

Fault

A fault in the Input circuit of the Input partner of a dual Input pair has been detected or unrecoverable detected faults affecting all inputs of the module.

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Safe Output status LEDs (Ox)

LED State

Safety Output Status

Description OFF

Good

Output is OFF, or module being configured

YELLOW

Good

Output is ON

RED

Fault

A fault in the output circuit has been detected, or values received from network for the two outputs used as dual output pair are different.

BLINKING RED

Fault

A fault in the other output circuit has been detected (whatever the output mode configuration: single or dual) or unrecoverable detected faults affecting all outputs of the module.

Link and Network Activity Status LEDs (LINK)

LED State

Speed Negotiate

Description OFF

No network link.

BLINKING GREEN

100 Mbps Link is established with no activity.

GREEN

Link is established with activity.

BLINKING YELLOW

10 Mbps Link is established with no activity.

YELLOW

Link is established with activity.

Module Status LED (MOD)

LED State

Speed Negotiate

Description OFF

No power

No power applied to the device.

GREEN

Executing

The device is operating in a normal condition.

BLINKING GREEN

Idle state

The device is in the Idle or Standby State.

RED

Critical Fault

The device has an unrecoverable fault, may need replacing.

BLINKING RED

Self-test

The device is in Self-Test or the device needs commissioning due to configuration or TUNID missing, incomplete or incorrect.

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Network Status LED (NET)

LED State

Status

Description

OFF

No Power / No IP Address

The module is not online. The module may not be powered, look at Module Status LED (MOD).

FLASHING GREEN

Online / Not Connected

The module is Online but has no connection in the established state (IDLE mode).

GREEN

Link OK / Online / Connected

The module is Online and has connections in the established state (EXECUTING mode).

FLASHING RED

Connection Time-out

One or more I/O connections are in the timed–out state.

RED

Critical link failure

Failed communication device. The module has detected an error that has rendered it incapable of communicating on the network.

FLASHING

RED / GREEN

Communication faulted

A specific communication faulted (device uses this indication to allow maintenance personnel commissioning the TUNID in a safety device).

Module Configuration Lock Status LED (LOCK)

LED State

Mode

Description

OFF

either no configuration or

either configured by a CIP Safety Originator

The module is not configured or has been configured by a safety originator (FW Open Type 1).

YELLOW

Configuration Locked

Valid configuration received and locked.

FLASHING YELLOW

Configuration not Locked

Valid configuration received and not locked.

RED

Module faults

 Memory key missing  Bad safety configuration

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6. Product installation and wiring

This chapter describes wiring possibilities and associated Safety categories.

Power supply

The HarshIO safety module shall be powered with 2 separate power supplies:

- 1x 24 VDC for module logic and safety inputs power

- 1x 24 VDC for safety Outputs auxiliary power

Warning!

To comply with CE directive, the module shall be powered from a safety extra-low voltage (SELV) or a protected extra-low voltage source.

Note!

The 2 grounds are separated (means isolated from each other).

Warning!

 The maximum total current shall not exceed 8 A for Logic/Input power (UB).  The maximum total current shall not exceed 8 A for Output power supplies

power (UL).

 The current is monitored to be able to go in fail safe state if a current exceeds

the maximum.

Warning!

Personnel in charge of safety application must verify that the maximum current consumption is lower than the maximum limit on all the range of temperature supported.

Warning!

An overcurrent protection should be added before the HarshIO module to avoid destruction of the module in case of overcurrent situation.

The pin description of the module power connectors is able here:

 4-pin 7/8” power connector module versions  5-pin 7/8” power connector module versions

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Ethernet connection

Port Identification

The HarshIO safety module embeds a dual-port Ethernet switch identified by ETH1 and ETH2.

Wiring

By default, the HarshIO safety module is delivered to be compliant with ODVA recommendations:

 The left M12 connector (ETH1) shield is not connected to functional earth.  The right M12 connector (ETH2) shield is connected to the functional earth (FE)

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This configuration allows the following wiring:

ETHERNET SWITCH

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

Chassis

Ground

Chassis

Ground

Chassis Ground

Shield plate

position

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An external shield plate is provided to allow the connection between the two Ethernet shield connector, in order to achieve the following wiring:

ETHERNET SWITCH

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

LNK

ACT

10/

100

Chassis Ground

Shield plate

position #2

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Module grounding

Warning!

At least one of the earth connections shown on the schematics must be ground connected to ensure the good operation of the module.

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I/O wiring

The following table shows different safety I/O wiring with their corresponding safety categories:

Safety Input wirings

Single Channel

Device

Pulse test

from Test

Output

M12 Port Wiring

Safety

Category

Push Button

Yes

TP0 is

configured as

24 V power supply with

pulse test

1 2

TP0

IN0

IN1TP1

GND

Dry Contact

24 VDC

TP0 is

configured as

24 V power

supply

1 2

TP0

IN0

IN1TP1

GND

Dry Contact

24 VDC

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Dual Channel

Device

Pulse test

from Test

Output

M12 Port Wiring

Safety

Category

E-Stop or Door

Monitor

Yes

TP0 and TP1 are configured as 24 V power

supply with

pulse test

1 2

TP0

IN0

IN1TP1

GND

24 VDC

TP0 is

configured as

24 V power

supply

1 2

TP0

IN0

IN1TP1

GND

24 VDC

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Device

Pulse test

M12 Port Wiring

Safety

Category

Light Curtain

TP0 is

configured as

24 V power

supply

1 2

TP0

IN0

IN1TP1

GND

OSSD1

OSSD2

24VDC 24VDC

Emitter Receiver

3 or 4

depending

on light

curtain

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Safety Output wiring

Single Channel

Device

Pulse test

M12 Port Wiring

Safety

Category

Relay

Yes

OUT0 and

OUT1 are

configured as single channel with pulse test

1 2

OUT0

OUT1

GND

24VDC

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Dual Channel

Device

Pulse test

M12 Port Wiring

Safety

Category

Relay

Yes

OUT0 and

OUT1 are

configured as

dual channel

with pulse test

1 2

OUT0

OUT1

GND

24VDC

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Bipolar Safety Output wiring

Device

Pulse test

M12 Port Wiring

Safety

Category

Relay

Yes

1 2

OUT0

OUT124V

GND

Sourcing

Sinking

1 2

OUT0

OUT124V

GND

Sourcing

Sinking

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Muting Lamp wiring

Device

Pulse test

from Test

Output

M12 Port Wiring

Safety

Category

Muting Lamp

Yes

Feature only

available when

TO3 or TO7

are configured

as a muting lamp output

1 2

TP0

IN0

IN1TP1

GND

24VDC

Note!

A muting lamp is not a safety device.

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7. Product Deployment

This chapter presents an example of how to proceed with the commissioning of the HarshIO Safety modules based on the Molex SNCT configuration tool and Rockwell Automation RSLogix™ 5000 software version 20.

Getting Started

Warning!

Uncontrolled processes can lead to personal injury and material damages.

Warning!

Use only components complying with safety standard corresponding to the required safety level.

It is recommended to consult a certification body regarding the assessment of the entire system. You will need to define the type of safety components to be used, including the HarshIO Safety modules.

This will be necessary to calculate the parameters of the whole safety function. The safety function shall be the result of a risk assessment study.

IP address setting

The HarshIO module is configured in DHCP mode by default. When connecting to a network with a DHCP server, an IP address is automatically assigned to the module.

Setting IP address using the 3 rotaries

You can stop the DHCP procedure (in case of no DHCP server on the network) by selecting the 3 rotaries located in the window area of the module.

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Warning!

Use a plastic screw driver to turn the rotary switches or wear anti-static equipment.

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Positions and behavior of 3 rotaries

Mode

x100

rotary

x10

rotary

Descriptions

Static

Address

[0 to 2]

[0 to 9]

Overwrite the 4th byte of the IP address stored in Flash Memory.

IP Address: 192.168.1.xyz IP mask: 255.255.255.0 Gateway: 192.168.1.1 (except then the IP address is

192.168.1.1 then Gateway address is 0.0.0.0).

Note!

Addresses (xyz) in the range from 1 to 254 can be allocated. Invalid setting (e.g.

000 or 255 or 278…) lead to case (a,b,c

of this table).

Note!

The IP mask address and Gateway address are the ones stored in the Flash memory of the module.

To change these parameters, send explicit messages command to the module. See section here.

Note!

In this mode, it is not possible to store an IP address using CIP Explicit messages (0xF5 TCP/IP Object).

DHCP

Mode

4 u v

HarshIO module gets its IP address, IP mask address and gateway address according DHCP method.

Note!

This mode requires that a DHCP server equipment is active on the network to deliver IP addresses.

Note!

If u = v = 0  DHCP based on MAC address

If uv = [01 .. 99]  DHCP based on Client ID

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Note!

Module sends request indefinitely.

Note!

In this mode, it is not possible to store an IP address using CIP Explicit messages (0xF5 TCP/IP Object).

Update

Firmware

9 9 9

The module enters in the update FPGA and firmware mode.

Note!

Please contact Molex technical support for further information.

Stored

Address

(all other

rotary

positions)

a b c

HarshIO module gets its IP address, IP mask address and gateway address according information stored in its Flash memory.

Note! a,b,c designate any setting not described

as part of this table above (e.g. the following positions: 000, [255 .. 399], [500 .. 998]).

Note!

In this mode, it is possible to store the TCP/IP address information using an EtherNet/IP commissioning tools (using 0xF5 TCP/IP Object).

Note!

If the module has never been commissioned, the HarshIO starts in DCHP mode to obtain its first IP address.

Note!

The rotary switch position is ONLY read at the boot of the HarshIO module. Any modification of the position will require a power cycle (ON  OFF  ON) of the module.

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Note!

When changing DHCP to Stored mode, all the IP settings are saved in the modules (address, mask, gateway) as it was set during DHCP transaction (given by the DHCP server).

Warning!

After setting the IP address, the window shall be closed and not open anymore during working operation.

Warning!

The module window shall be screwed with a torque of 0.4 Nm to ensure a correct sealing to achieve IP67 rating.

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Setting module IP address using EtherNet/IP Explicit Messages

1. Use of Molex EtherNet/IP Tools To change the IP settings of the module, you have to use a software tool like Molex EtherNet/IP Tools

that manages Explicit Messaging requests to access module CIP objects (0xF5 TCP/IP) to set parameters like:

 Static or dynamic IP addressing  IP address  Network mask  …

The Molex EIP_Tools software can be download free-of-charge here.

There is no installation setup. Just copy the files in a new folder and launch EIP_Tools.exe.

Click on Options

Select the computer network Ethernet interface and click OK.

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Select Send List Identity Request on UDP to discover all the EtherNet/IP devices connected to the network. Then select by clicking one EtherNet/IP device in the station list. The device selected should have its IP address set in the Station: <IP> area.

Click on 0xF5 TCP/IP tab and then on Get_Attribute_All. The device parameters are displayed.

For example to modify the IP Address parameter, write the new IP and select Set_Attribute button to send the command.

1 2 3 4 1 2 3

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Note!

The module is now configured with a new IP address stored in its flash memory. Set the 3 rotary switches located in the window of the module to the position 000.

Restart the module to apply the new IP address.

EDS files

The EDS files are simple text files used by network configuration tools to help identifying products and easily commission them on a network.

For example below a screen shot of Molex EtherNet/IP Scanner Configuration Tool (SNCT Master) showing the commissioning of EtherNet/IP CIP Safety HarshIO module using its EDS file.

- Molex EtherNet/IP SNCT Master -

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EDS file list according the associated HarshIO EtherNet/IP CIP Safety module versions:

4-pin 7/8” power connector versions

SAP #

Material #

EDS File Name

Product Code

112095-5107

TCDEC-8B4P-DYU-GW

0008002306220100.eds

1570 - 0x622

112095-5127

TCDEC-8B4P-DYU-G8

0008002306220100.eds

1570 - 0x622

112095-5108

TCDEC-8B4B-DYU-GW

00080023062A0100.eds

1578 - 0x62A

112095-5128

TCDEC-8B4B-DYU-G8

00080023062A0100.eds

1578 - 0x62A

5-pin 7/8” power connector versions

SAP #

Material #

EDS File Name

Product Code

112095-5111

TCDEC-8B4P-D1U-GW

0008002306120100.eds

1554 - 0x612

112095-5129

TCDEC-8B4P-D1U-G8

0008002306120100.eds

1554 - 0x612

112095-5112

TCDEC-8B4B-D1U-GW

00080023061A0100.eds

1562 - 0x61A

112095-5130

TCDEC-8B4B-D1U-G8

00080023061A0100.eds

1562 - 0x61A

From USB Stick

The HarshIO module EDS files are available on the USB stick delivered in the product package and located in the \EDS files folder.

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From Molex web site

The EDS files as well as the product documentation can be downloaded from the Molex web site.

http://www.molex.com/molex/mysst/DownloadCenter.action

and use “Option 1 - Select the Product Lines and/or Search by part number” to look for TCDEC-8xxP-DxU-Gx part number.

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Upload EDS from the module

The EDS file can also be uploading from the HarshIO modules. A tool like Rockwell RSLinx software can be used to call the Upload EDS from device service.

See the next section Import HarshIO Safety EDS into Rockwell hardware description library for further details.

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Import HarshIO Safety EDS into Rockwell hardware description library

To start the commissioning, the first step is to import the HarshIO Safety EDS file into Rockwell hardware library by using Rockwell Automation RSLinx™ software.

Start Rockwell RSLinx software.

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Select Menu Communications/Configure Drivers…

Select EtherNet/IP Driver

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Set a name for the Driver.

If there is multiple network interfaces in the computer, select the correct one to communicate with the HarshIO module.

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Check that the Driver is running.

RSLinx is now browsing the network to detect the EtherNet/IP devices. At this stage, the HarshIO Safety module is detected but appears with an icon representing a question mark because the EDS file is not yet imported.

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Select the HarshIO module, right-click on mouse and select Upload EDS file from device

A new tool is launch. Select Next button.

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The EDS Wizard is checking the EDS file revision in the device.

The EDS Wizard is checking integrity of the EDS file.

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The EDS Wizard is checking integrity of the icon file.

The EDS Wizard is importing the EDS file and icon in the Rockwell hardware library.

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The EDS Wizard has successfully imported the files.

RSLinx has registered correctly the EDS file and displays now the correct icon of the HarshIO eIP module.

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Configure HarshIO Safety module into Rockwell RSLogix 5000 project

Start RSLogix5000 software.

Select the Ethernet node of the EtherNet/IP connectivity channel.

Right-click on mouse and select New Module…

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Look and select in the Catalog Generic EtherNet/IP Safety Module.

Select the module, right-click on mouse and select Create

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99  IP67 Safety Digital I/O Modules

Give a Name and set the module IP address that has been discovered by RSLinx.

RSLogix software creates automatically a Safety Network Number (also called SNN). The Safety Network Number is a unique identifier of 48-bit number to prevent the acceptance of connection requests that have been misdirected. This is to ensure that every module on the safety network can be uniquely identified.

Warning!

Safety controllers (Originator) that have an “Automatic” SNN setting feature should only

use that feature when the safety system is not being relied upon

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EtherNet/IP™ CIP Safety™ IP67 HarshIO 600

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100  IP67 Safety Digital I/O Modules

In the Connection Parameters area, select Change

In the Module tab, change the following parameters:

 Vendor: 8 (Molex)  Product Type: 35  Product Code: 1570

Safety I/O assemblies

The Input Data and Output Data shall be set to Safety.