Connect industrial safety controllers to sensors & actuators

20th January 2016

Nat Bowers

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Reliably connecting industrial safety controllers to sensors and actuators in harsh duty environments, the Brad HarshIO Ethernet modules have been introduced by Molex. The machine mountable and IP67 rated modules are suited for industrial applications where liquids, dust or vibration may be present, and have been tested to withstand shock, high-vibration and high temperatures.

The Brad HarshIO modules are designed for safety applications, up SIL3 (Safety Integrity Level 3), Cat4/Ple, where communication over EtherNet/IP is needed to exchange safety and standard control data and diagnostics information over a single Ethernet network.

The compact modules offer 12 safe inputs and four safe outputs, supporting connection of single and dual channel safety devices - suited for automotive applications running robots in cells. The digital inputs and outputs can connect to both standard and safety rated sensors and utilises test pulses for connected standard outputs to perform diagnostics on panel lamps, buzzers and standard actuators. An overmoulded on-board memory key, available internally or M8, stores the configuration allowing module replacement in a minute without any special tools or re-commissioning.

Advanced features such as built-in 2-port Ethernet switch with DLR, diagnostic LEDs and a flexible IP address-setup method make configuration and operation simple. The integrated 2-port switch with DLR can be daisy-chained, allowing the user to wire the entire application without switches, thus achieving cost savings. Machine space is saved with the use of Molex M12 Ultra-Lock push-to-lock connectors allowing sensing devices or actuators to plug directly into the I/O module, creating an IP67 environmentally sealed Ethernet connection. The HarshIO modules are compact; the overall product dimensions being just 240x62x46mm (9.44x2.44x1.77”).

The units are Rockwell Automation ready and are compatible with all Rockwell GuardLogix controllers. Commissioning is made easy with Molex’s SNCT software and Rockwell Automation’s Studio 5000 Logix Designer application. (Note according to RA The Logix Designer application is the rebranding of RSLogix 5000 software.) Certification and regulatory approvals for the modules include TÜV and ODVA, conforming to EN 61508 SIL3, Cat4/Ple according to ISO 13849-1, CE, RoHS, REACH, UL/cUL, Korean CC and China (CCC).