molex Brad HarshIO 600 User manual

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User’s Manual
HarshIO 600
IP67 Motor Drive Roller IO Module for
EtherNET/IP
Brad™ from Molex
Version 1.4
October 24th, 2018

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Revision History
Date
Author
Changes
Revision
May 22th, 2018
Samuel Savary
Initial version
1.0
June 5th, 2018
Samuel Savary
Fixing information added (Dimension chapter)
1.1
July 2sd, 2018
Samuel Savary
MOD Led behavior & Operating temperature
1.2
October 9th, 2018
Youssef Ouassif
- Dynamic Braking of Itoh Denki motor
- General diagnostic on Drive rollers added to
Web Server
- Minor changes
1.3
October 24th, 2018
Samuel Savary
Interroll & Itoh Denki speed table update
1.4
Although every effort has been made to ensure the accuracy of this document, all information is subject to
change without notice. Molex takes no liability for any errors in this document or for direct, indirect, or
consequential damage resulting from the use of this manual.

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STATEMENT OF LIMITED WARRANTY
Brad™from Molex, manufacturer of HarshIO products, warrants to Buyer that products, except software,
manufactured by Brad™will be free from defects in material and workmanship. Brad™obligation under this
warranty will be limited to replacing the defective parts within one year of the date of purchasing. Products may
be returned by Buyer only after permission has been obtained from Brad™. Buyer will prepay all freight
charges to return any products to the facility designated by Brad™.
Brad™further warrants that any software supplied as part of a product sale, except obsolete products, will be
free from non-conformances with Brad™published specifications for a period of 90 days from the time of
delivery. While Brad™endeavors to improve the features and performance of software associated with its
products, no effort on the part of Brad™to investigate, improve or modify HarshIO modules firmware at the
request of a customer will obligate Brad™in any way.
For the convenience of existing customers, Brad™continues to supply certain products that are classified as
obsolete. No warranty on the software features of these products is stated or implied and Brad™specifically is
not obligated to improve the design of these products in any way. Information about the status of any product
is available upon request and customers are advised to inquire about the status of older products prior to
making a purchase.
This limited warranty does not cover losses or damages which occur in shipment to or from Buyer or due to
improper installation, maintenance, misuse, neglect or any cause other than ordinary commercial or industrial
applications. In particular, Brad™makes no warranties whatsoever with respect to implied warranties of
merchantability or fitness for any particular purpose. All such warranties are hereby expressly disclaimed. No
oral or written information or advice given by Brad™or Brad's representative shall create a warranty or in any
way increase the scope of this warranty. This limited warranty is in lieu of all other warranties whether oral or
written, expressed or implied. Brad’s liability shall not exceed the price of the individual units, which are the
basis of the claim. In no event shall Brad™be liable for any loss of profits, loss of use of facilities or device, or
other indirect, incidental or consequential damages.
Although every effort has been made to ensure the accuracy of this document, all information is subject to
change without any notice. Brad™takes no liability for any errors in this document or for direct, indirect, or
consequential damage resulting from the use of this manual.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many
variables and requirements associated with any particular installation, Brad™ cannot assume responsibility or
liability for actual use based on the examples and diagrams.
COPYRIGHTS and TRADEMARKS
Reproduction of the contents of this manual, in whole or in part, without written permission of Brad™is
prohibited.
Mini-Change®, Ultra-Lock™, Brad™ are all registered trademarks of Molex, Inc.
All other products or trademarks are the property of their respective owners.

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Table of contents
1. General Safety Instructions ................................................................6
General information.................................................................................................6
Personnel qualifications ..........................................................................................6
Preventive messages..............................................................................................6
Usage compliance...................................................................................................6
Device installation and set-up .................................................................................7
Device operation .....................................................................................................8
Electrical, mechanical and thermal specifications...................................................8
Preventive and corrective maintenance..................................................................8
2. General description.............................................................................9
Introduction..............................................................................................................9
Overview ...............................................................................................................10
3. Technical Data ...................................................................................17
Dimensions (mm)..................................................................................................17
Power Data............................................................................................................18
Electrical Signal Data............................................................................................18
EtherNET/IP ..........................................................................................................20
Mechanical and Environmental Data ....................................................................21
4. System Description ...........................................................................22
Physical description...............................................................................................22
Power connector ...................................................................................................23
Ethernet connectors and encoding switches ........................................................26
I/O connectors.......................................................................................................30
MDR connectors....................................................................................................32
Protective and functional earth connection...........................................................34
5. I/O Data mapping ...............................................................................36
I/O Messaging .......................................................................................................36
EtherNet/IP Assembly instances...........................................................................37
Assembly #101 –Input Process & Error Status Data...........................................38
Assembly #102 –Input Process, Error Status & Operating information Data ......39
Assembly #103 –Output Process & Control Data................................................40
Assembly #104 –Output Process / Control Data & Reset Operating information43
Assembly #105 –Configuration Data....................................................................44
6. MDR Features & Behaviors...............................................................44
MDR Startup..........................................................................................................44
MDR Operating Speed..........................................................................................45
7. Getting started ...................................................................................46
Packaging content.................................................................................................46
Out of box settings ................................................................................................46
Connection instructions.........................................................................................46
Rockwell Studio 5000............................................................................................47
8. Web Server Interface.........................................................................48

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Hardware/Firmware Module information...............................................................48
Ethernet network information ................................................................................49
EtherNET/IP diagnostic information......................................................................50
Event logger ..........................................................................................................51
Power supply information and channel status ......................................................52
Motorized Drive Roller information......................... Error! Bookmark not defined.
Energy...................................................................................................................57
9. EtherNet/IP Object Classes...............................................................58
Identity (0x01)........................................................................................................58
Message Router (0x02).........................................................................................60
Assembly (0x04)....................................................................................................61
Connection Manager (0x06)..................................................................................62
TCP/IP Interface (0xF5) ........................................................................................63
Ethernet Link (0xF6)..............................................................................................64
File (0x37) .............................................................................................................65
DLR (0x47)............................................................................................................66
QoS (0x48)............................................................................................................67
10. Firmware update................................................................................68
11. Product Support ................................................................................68
Technical Support .................................................................................................68
Web Site................................................................................................................69

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1.General Safety Instructions
General information
The current documentation is intended for persons technically qualified to install, use and service the products
described herein. It contains the necessary information for proper use of the products. However, for advanced
use of our products, please contact your nearest dealer for additional information.
The content of this documentation is not binding and cannot extend or limit warranties.
Personnel qualifications
Only qualified persons are authorized to install, use and service the products. Use by unqualified persons or
failure to follow the safety instructions of this document, the manuals and/or those affixed to the devices, can
result in irremediable harm or damage to persons and equipment. The following personnel are deemed to be
qualified persons for:
•Equipment operation: Personnel who operates the machines and/or processes connected to the
Brad™ products. Brad™ HarshIO must be used by persons who have received training and have
been informed of the major risks involved in working in an industrial environment.
•Preventive and corrective maintenance: Persons who modify Brad™ products hardware and software
configuration and install the product updates supplied by the manufacturer. These persons must:
obe trained in Brad™ products and operation
ohave the experience and technical knowledge required to be aware of the risks (electrical
hazards in particular) involved in their job and the ways of reducing these risks for
themselves, third parties and the equipment being used.
Preventive messages
Preventive messages are designed to identify the particular risks likely to affect personnel and/or hardware.
Different message types, both in the documentation and on the products, indicate different degrees of risk:
Danger messages indicate immediate hazards that could result in death or serious injury if not averted.
Warning messages indicate situations that could result in death, serious injury or material damage.
Caution messages indicate potentially dangerous situations that could cause bodily harm or material damage.
Usage compliance
The products described in the current documentation comply with currently applicable European
Directives (EC labeling). However, they can only operate correctly with the applications for which they were
intended as described in the documentation, and with approved products.

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As a general rule, if all the handling, transportation, and storage recommendations and installation, operation
and maintenance instructions are followed, the products will operate correctly without risk for personnel or
hardware.
Device installation and set-up
It is important to follow the rules below when installing and setting up the Brad™ HarshIO. If system installation
includes products more than thirty meters away from each other, the basic cabling rules must be closely
followed.
•Strict compliance with the safety instructions provided in this documentation or on the equipment to be
installed and implemented, is absolutely essential.
•Make sure that the installation is carried out in compliance with regulations of the user country,
•Install the equipment in a suitable environment. As a closed equipment, the Brad™ HarshIO may be
installed in two ways:
oIn a casing (cabinet, chest) or,
oDirectly without any additional protection, if the associated systems (power supply, cables,
sensors, etc.) already carry a protection index equivalent to IP67 or higher.
Always connect the Brad™ HarshIO to the protective earth (PE) in compliance with existing standards (for
example: use the green/yellow wires in accordance with the NFC 15 100 standard).
•LV (Low Voltage) circuits must have a protective earth connection to ensure dangerous voltage
detection.
•Before powering up the device, check that the nominal voltage is the same as the mains voltage.
•Only use Extra Low Voltage power supplies (PELV-/SELV-) which comply with existing standards.
•Check that the power voltages are within the tolerance ranges defined in the technical specifications
for the devices.
•Always ensure that power restoration (immediate, hot or cold) will not create a hazard for personnel or
equipment.
•Ensure that emergency stop devices remain effective in any equipment operation mode, even when
abnormal (for example, in the event of a cut wire). Resetting these devices should not result in
uncontrolled or undefined restarts.
•Position the signal cables so that the automation functions will not be disrupted by any capacitive,
inductive or electromagnetic influences, etc.
•Install the automation devices and their controlling devices so that they are protected against any
adverse incident.
•Adequate safety precautions must be applied to inputs and outputs to prevent the lack of signals from
causing undefined states in the automation devices.

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Device operation
Because Brad™ HarshIO devices are components of a control system, the safety of the entire automated
system, including that of the installation and the application, cannot be dealt with in this document. For further
information, see IEC 61131-4, describing risk reduction measures for PLC users.
See the documentation of the specific products involved for more information on operation safety.
Electrical, mechanical and thermal specifications
Detailed information about the electrical, mechanical and thermal specifications of the device is available in the
associated technical documentation (installation manuals, service instructions).
Preventive and corrective maintenance
Servicing
•When replacing parts or components, only use factory approved parts.
•In all cases, before servicing a Brad™ HarshIO, disconnect the power supply from the device (unplug
the power cord or open the power cut-out device).
•Before servicing an onsite mechanical Brad™ HarshIO, disconnect its power supply and mechanically
lock the moving parts.
•On positive logic outputs or negative logic inputs, take all the necessary precautions to prevent any
disconnected wires from coming into contact with the mechanical ground (risk of unwanted
commands).
Product end-of-life
Contact your local dealer for information on how to dispose of used products in compliance with current
regulations.

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2.General description
Introduction
Brad™ HarshIO 600 EtherNET/IP Motorized Drive Roller IO module (also called HarshIO) is a reliable
solution for connecting industrial controllers to Motor Drive Rollers & I/O devices in harsh duty environments.
Contained in an IP67 rated housing, Brad I/O modules can be machine mounted and are able to withstand
areas where liquids, dust or vibration may be present. This makes them ideally suited for many applications
including material handling and automated assembly.
All Brad™ HarshIO modules, with Micro-Change®(M12) ports,
accept both standard threaded cordsets and the Molex
Ultra-Lock™ system.
Ultra-Lock™ connection System! The fastest, easiest and most
secure connection ever designed. Ultra-Lock™ technology is
designed for higher performance and reliability. Discover how the
push-to-lock technology of the Ultra-Lock connection system can
eliminate your downtime, increase your productivity and lower your
costs. More information visit: www.molex.com .
Brad™ HarshIO includes advanced diagnostic features. Each module embeds visible LEDs to provide
maintenance personnel the ability to easily determine I/O module and network status. These statuses are also
available through the process data image or via extended slave diagnostics.
Brad™ HarshIO main features include:
▪Module is housed in an IP67 rated enclosure that when properly installed—according to IEC 60529—
provides protection against the ingress of dust, water
▪8 digital user configurable I/O channels (DIO) + 4 ports for Interroll or Itoh Denki Motor Drive Roller
control.
▪4 or 5-pole Mini-Change (7/8) power supply connector
▪Digital input and output short circuit protection
▪Integrated 2-port unmanaged Ethernet switch with cross-over and MRP capabilities
▪Diagnostic visible LEDs
▪Rotary switches for IP address, firmware update and factory reset modes
▪ODVA Conformance tested
▪Certifications:
oCE compliant for all applicable EC directives
oFCC Title 47, Part 15, Subpart B, Class A
oProtection against electrical shocks IEC 61131-2:2007 Chap 12/13/14
oEMC directive for industrial use
oUL94-V1
oODVA certified
Part Number Table
SAP No
Material No
Description
112095-5156
TCDEI-8YMP-DYU-G
IP67 module for EtherNET/IP, 4-pin power supply connector with
Isolated grounding, 8 digital user configurable I/O channels
(DIO) + 4 ports for Interroll & Itoh Denki Motor Drive Rollers
control.
112095-5157
TCDEI-8YMP-D1U-G
IP67 module for EtherNET/IP, 5-pin power supply connector with
Isolated grounding, 8 digital user configurable I/O channels
(DIO) + 4 ports for Interroll & Itoh Denki Motor Drive Rollers
control.

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Overview
The HarshIO module is consisted of three main parts.

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Power distribution
HarshIO module can be powered up through 4/5-pole Mini-Change (7/8”) male power supply connector. It can
supply or transfer total amperage of 8A per pin.
The maximum power cable length shall be 30 meters. This is a recommendation
but not a limitation. The module will still work if the cable is longer. The danger is
potentially to destroy the module if a lightning occurs (very rare).
It can be powered by 2 separate power supplies:
•UB power supply is used to power:
oModule’s logic
oSensor power (Pin 1)
oDigital Inputs / Outputs channels (C0 to C7)
•UL power supply is used to power the motor drive rollers
oThere is no separate grounding between UB and UL. It means that 0V (UB) and 0V (UL) are connected.
The +24 voltage can be applied on UB and UL from separate or unique power supply source.
Note!
UB & UL support a power interruption according to EN 60204-1.

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Network topologies
HarshIO EtherNET/IP modules can be used with a protocol compliant controller as part of control system
architecture. The built-in unmanaged 2-port Ethernet switch allows flexibility in the network topology to meet
your application needs. These topologies include the following:
•Star
•Daisy-chain
•Ring (using DLR protocol)
•Combination of all above
Star topology
Star topology allows you to connect mixed I/O modules or additional equipment. This topology allows
maintenance on one module –for example, by removing the network cable, or by power cycling to the module
–without affecting the other modules.
HMI
Ethernet
Switch
PLC
Daisy-chain topology
The daisy-chain topology allows you to connect I/O modules or additional equipment in one line, from one
device to the next in an optimized way along the production line.
When considering the daisy chain topology, note that
•If a module, somewhere in the middle of the chain, has the network cable disconnected or power to the
module is removed then communications to any module located down the chain will be lost.
•The embedded dual port Ethernet switch located in each module eliminates the need for additional
Ethernet switches.
HMI
Ethernet
Switch
PLC

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Ring topology
Ring topology allows you to include mixed HarshIO modules and additional devices in a ring. Performing
maintenance on one module –for example, by removing the network cable, or by removing a module –does
not affect other modules as the disruption can be detected and the EtherNET/IP communication can be then
routed adequately. To manage the ring, a protocol called DLR (Device Level Ring) is required.
Note
When considering DLR ring topology:
A device called DLR Supervior shall be present in the ring to control the
administration and detects the network failures. The other participants are
called DLR Devices.
Combination of various topologies
Combining star and daisy-chain topologies allows you to connect HarshIO modules with mixed HarshIO
modules or additional network devices.
HMI
Ethernet
Switch
PLC

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Signal
The HarshIO module supports up to 8 I/O ports:
•4 I/O ports with 8 standard input / Output user configurable channels. (C0 to C7).
•4 M ports for Motor Drive Roller (M0 to M3).
The I/O ports with configurable digital output on Pin 2 / Pin 4 can deliver up to 2A (4A Peak) for actuators with
high power requirements.
The M port for Motorized Drive Roller (MDR) can control the following rollers:
•Interroll EC310
•Itoh Denki PM500XE / PM500XP
Only 1 MDR can be connected on each M port. Up to 4 Interroll EC310 or 4 Itoh Denki PM500XE/XP can be
connected at the same time (See below). But no mixed Interroll / Itoh Denki MDR configuration is supported.
4 I/O configurable ports
4 Motor Drive Roller ports

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Typical application
Brad® MDR Conveyor Classic HarshIO Modules provide a reliable solution when connected with commonly
used 24V DC Motorized Drive Rollers (MDR’s).
Contained in an IP67 rated housing, Brad® MDR Conveyor Classic HarshIO Modules can withstand areas
where liquids, dust or vibration may be present, making them ideal for use in material handling applications.
For general motorized roller conveyor, it avoids protecting the IO module and its wiring by an enclosure
constructed with conveyor frame and frame cover conform to UL50 Type 1 or greater.
NOTE
The MDR can be connected to the M port via 5 wires M12/M8 converter cable with a
maximum length of 3m.

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3.Technical Data
Dimensions (mm)
The following figures show the external dimensions of the I/O module.
NOTE
When fixing the MDR module, tighten all the four screws otherwise the module may be
greatly affected by vibration, causing failure of the module. When installing the module,
tighten screws within the following torque range:
- M4 Mounting screw: 0.83 to 1.11 Nm.
- M3 Screw for a Functional Earth metal fitting: 0.43 to 0.57 Nm.
36
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Power Data
Module
4/5-pin power version
Power IN connector
Mini Change (7/8”), 4/5-pin, male, Maximum 8 A
Module & Input power (UB)
24 VDC, -20%/+25% (19.2 VDC / 30 VDC) protected against power crossing)
Warning, a voltage over 30 VDC may destroy the module
Operating current (UB)
90 mA (no I/O device connected)
Operating current (UL)
20 mA (no I/O device connected)
Max current consumption (UB)
8.2 Amps
Output Power (UL)
24 VDC, -10%/+10% (21.6 VDC / 26.4 VDC) for Itoh Denki
24 VDC, -10%/+10% (21.6 VDC / 28 VDC) for Interroll
(protected against power crossing)
Warning, a voltage over 30 VDC may destroy the module
Max current consumption (UL)
8.2 Amps
Galvanic isolation between UB & UL
500 V min
Electrical Signal Data
I/O Ports
I/O Ports
Max draw current per I/O ports
4 A
Sensor power pin
Pin 1 (L+ / Sensor power supply)
Sensors draw current from
UB
Sensors draw current (Pin 1)
200mA Nominal / 400mA Peak
Channels
Pin 2 (configured as)
Pin 4 (configured as)
Standard Digital Inputs
Number of Channel
4 channels max
4 channels max
Input type
PNP, compliant to IEC 61131-2 Type 3
PNP, compliant to IEC 61131-2 Type 3
On-state current
2.5 mA typ.
2.5 mA typ.
Off-state current
1 mA max.
1 mA max.
Input channel voltage (“1”)
10 V … 30 V
12 V … 30 V
Input channel voltage (“0”)
-5 V … 5 V
-5 V … 9 V
Input filter
1ms
1ms
Standard Digital Outputs
Outputs draw current from
UB
UB
Channels
4 channels max
4 channels max
Output voltage (min)
UB –1V
UB –1V
Output type
PNP, current sourcing
PNP, current sourcing
Output current
2 A per channel (4A peak)
2 A per channel (4A peak)
Maximum output current
8.0 A at 25°C: total for all outputs combined
8.0 A at 25°C: total for all outputs combined with
all sensor supply current
Short circuit current (typical)
up to 6.5 A
up to 6.5 A

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MDR ports
MDR port
Pin 1 (UL)
Pin 2 (output)
Pin 3 (GND)
Pin 4 (I/O)
Pin 5 (analog)
Operating current
2A nominal / 6A peak
24mA nominal
/
24mA nominal
/
Operating voltage
+24VDC
+24VDC
/
+24VDC
0-10VDC
Input type
/
/
/
PNP, compliant to
IEC 61131-2 Type 3
/
Output type
/
PNP, current sourcing
/
PNP, current
sourcing
/
Warning!
The digital outputs of the product are internally protected against voltage spike due to
inductive load switching. Nevertheless, an external protection (freewheeling diode)
could be added if necessary.
Note!
Shields of I/O connectors are not connected to earth. If shielded cable is used, then
customer should connect the cable shield to the earth.

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EtherNET/IP
EtherNET/IP Fieldbus
Ethernet connectors
2 x M12, 4-pin, female, D-Coded, shielded
IP setting
DHCP (based on MAC & on Client_ID), Static IP, Stored IP
Protocol
EtherNet/IP Adapter according specification Vol 1-3.17 (CIP) and Vol 2 –1.18 (EtherNet/IP)
Data access
Implicit messages for I/O data transfer
Communication Class
Real Time Conform Class B (RT CC-B) –No IRT supported
Implicit (I/O) connection
• 1x Exclusive Owner (EO) connection (with configuration data only)
• Up to 7 Listen Only (LO) connections (with or without configuration data) • Up to 8 Input
Only (IO) connections (with or without configuration data)
• 8 simultaneous connections (Ex: 1EO+ 4IO +3LO)
Explicit (EM) connection
Up to 8 Class 3 connections (Connected and unconnected)
Supported CIP Objects
• 0x01 – Identity
• 0x02 – Message Router
• 0x04 – Assembly
• 0x06 –Connection Manager
•0xF5 –TCP/IP Interface
• 0xF5 – Ethernet Link
• 0x37 – File (EDS Upload)
• 0x47 – DLR
• 0x48 – QoS
Integrated Switch
•2x ports integrated switch (with MRP capability)
•Speed: 100Mbps
•Auto negotiation
•Auto crossing
•Auto polarity
•1x status Led / port
•Storm Protection against network loop (Broadcast, Multicast and Unicast packets)
Ethernet Packet
Manage up to 9000 packet/sec
Request Packet Interval (RPI)
from 1 ms up to 65535 ms (default 30 ms)
IP Address Conflict Detection
Yes
Quick Connect
Yes
DLR (Device Level Ring)
Yes (Ring Node, Beacon-Based)
QoS (Quality of Service)
Yes (Layer 3 supported only)
ODVA conformance
Yes (CT15)