molex BradControl HarshIO 600 eIP User manual

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User’s Manual
HarshIO 600 eIP
IP67 Digital I/O Modules for EtherNet/IP
Isolated Grounding and QuickConnect Versions
BradControl™ from Molex
Version 2.6
March 25th, 2013

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Revision History
Date
Author
Changes
Revision
January 24, 2012
E. GORY
Release version
1.0
February 06, 2012
E. GORY
Various typo corrections
Hyperlink to Molex Support and Download page
1.1
February 13, 2012
E. GORY
Various typo corrections
1.2
March 20, 2012
E. GORY
DHCP lease
1.3
September 06, 2012
E. GORY
Add 5-pin power supply module versions
Add 4-pin power 12IN/4OUT module version
2.0
September 14, 2012
E. GORY
Typo corrections
2.1
September 27, 2012
E. GORY
Typo corrections
2.2
December 11, 2012
E. GORY
Update mapping with power diagnostic bits
Add ground stub
Add EIP-Tool information and link
2.3
December 17, 2012
E. GORY
Correction 4-pin power supply wiring
Set Attribute 12 of CIP TCP/IP object (0xF5)
2.4
January 10, 2013
E. GORY
Update Listen Only (LO) connection information
2.5
March 25, 2013
E. GORY
Update default module settings
Add Chapter 9 - Web server interface
Update Chapter 8 for RXLogix 5000 v20
2.6
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
BradControl™ from Molex, manufacturer of HarshIO products, warrants to Buyer that products, except
software, manufactured by BradControl™ will be free from defects in material and workmanship.
BradControl™ obligation under this warranty will be limited to repairing or 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 BradControl™. Buyer will prepay all freight charges to return any products to the repair facility
designated by BradControl™.
BradControl™ further warrants that any software supplied as part of a product sale, except obsolete products,
will be free from non-conformances with BradControl™ published specifications for a period of 90 days from
the time of delivery. While BradControl™ endeavors to improve the features and performance of software
associated with its products, no effort on the part of BradControl™ to investigate, improve or modify HarshIO
modules firmware at the request of a customer will obligate BradControl™ in any way.
For the convenience of existing customers, BradControl™ continues to supply certain products that are
classified as obsolete. No warranty on the software features of these products is stated or implied and
BradControl™ 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, BradControl™ 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 BradControl™ or BradControl™'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. BradControl™’s liability shall not exceed the price of
the individual units, which are the basis of the claim. In no event shall BradControl™ 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. BradControl™ 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, BradControl™ 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 BradControl™is
prohibited.
Mini-Change®, Ultra-Lock™, BradControl™ 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
3. System Description ...........................................................................11
Overview ...............................................................................................................11
Typical application.................................................................................................14
Quick Connect applications...................................................................................15
4. Module Characteristics .....................................................................18
Hardware characteristics.......................................................................................18
Mechanical characteristics....................................................................................22
Physical I/O mapping ............................................................................................23
I/O messaging .......................................................................................................27
I/O data mapping...................................................................................................28
Pin assignment......................................................................................................36
Separate grounding wiring for application using safety relays..............................38
Port wiring type......................................................................................................40
LED assignment....................................................................................................41
Network IP address setting ...................................................................................42
Display information................................................................................................45
Hardware address (MAC Address) .......................................................................46
EDS files................................................................................................................46
5. Specific Behavior...............................................................................47
I/O behavior...........................................................................................................47
IDLE behavior........................................................................................................47
Duplicate IP address.............................................................................................47
6. EtherNet/IP Object Classes...............................................................48
Identity (0x01)........................................................................................................48
Message Router (0x02).........................................................................................49
Assembly (0x04)....................................................................................................50
Connection Manager (0x06)..................................................................................51
TCP/IP Interface (0xF5) ........................................................................................52
Ethernet Link (0xF6)..............................................................................................53
7. Getting Started...................................................................................54
Packaging content.................................................................................................54
Accessories...........................................................................................................54
Getting Started ......................................................................................................55

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8. Configuration using RSLogix 5000 ..................................................57
ESD File ................................................................................................................57
Commissionning HarshIO eIP in Rockwell Logix 5000 version 20.......................58
Commissionning HarshIO eIP in Rockwell Logix 5000 version 17.......................74
9. Web Server Interface.........................................................................76
IP and Physical information...................................................................................77
Network Interface information ...............................................................................78
EtherNet/IP information.........................................................................................79
10. Earth Connection...............................................................................80
11. Cables and Cordsets.........................................................................82
Industrial Ethernet cables......................................................................................82
I/O cables ..............................................................................................................88
Power supply cables .............................................................................................94
12. Product Support ................................................................................96
Product Information...............................................................................................96
Technical Support .................................................................................................96

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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 and
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

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intended as described in the documentation, and with approved products.
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 FELV (Functional Extra Low Voltage) power supplies 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 1131-4, 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
BradControl™ HarshIO eIP (EtherNet/IP) modules provide a reliable solution for connecting industrial
controllers to I/O devices in harsh duty environments. Contained in an IP67 rated housing, BradControl 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 equipment and
automated assembly machinery.
All BradControl™ HarshIO 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 your
downtime, increase your productivity and lower your costs. More
information visit: www.molex.com .
BradControl™ HarshIO 600 includes advanced diagnostic features. Each module embeds visible LEDs
to provide for 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 telegram.
BradControl™ HarshIO 600 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
16x digital channels with up to 1ms I/O cycle time
Integrated 2-port unmanaged Ethernet switch with cross-over capability
Isolated grounding to able to use 2 separate power supplies to power the module logic/input
ground and the module output ground for safety application
Digital input and output short circuit protection
Quick Connect feature to power up and run the HarshIO module in less than 500ms for robotic
application where I/O are control on a tool changer
BradControl™ HarshIO 600 is available in various combinations:
16x Inputs
16x Outputs
8x Inputs + 8x Outputs
12x Inputs + 4x Outputs
Whatever the combination, the digital inputs and outputs are always PNP.

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Part Number Table
4-pin power connector versions
SAP No
Material No
Description
112095-5040
TCDEI-8D0P-DYU-G
IP67 module for EtherNet/IP, 4-pin power supply connector,
16 PNP Inputs, Isolated grounding and QuickConnect
112095-5041
TCDEI-888P-DYU-G
IP67 module for EtherNet/IP, 4-pin power supply connector,
8 PNP Inputs + 8 Outputs, Isolated grounding and QuickConnect
112095-5043
TCDEI-8B4P-DYU-G
IP67 module for EtherNet/IP, 4-pin power supply connector,
12 PNP Inputs + 4 Outputs, Isolated grounding and QuickConnect
112095-5042
TCDEI-80DP-DYU-G
IP67 module for EtherNet/IP, 4-pin power supply connector,
16 Outputs, Isolated grounding and QuickConnect
5-pin power connector versions
SAP No
Material No
Description
112095-5060
TCDEI-8D0P-D1U-G
IP67 module for EtherNet/IP, 5-pin power supply connector,
16 PNP Inputs, Isolated grounding and QuickConnect
112095-5061
TCDEI-888P-D1U-G
IP67 module for EtherNet/IP, 5-pin power supply connector,
8 PNP Inputs + 8 Outputs, Isolated grounding and QuickConnect
112095-5063
TCDEI-8B4P-D1U-G
IP67 module for EtherNet/IP, 5-pin power supply connector,
12 PNP Inputs + 4 Outputs, Isolated grounding and QuickConnect
112095-5062
TCDEI-80DP-D1U-G
IP67 module for EtherNet/IP, 5-pin power supply connector,
16 Outputs, Isolated grounding and QuickConnect

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3.System Description
Overview
HarshIO eIP modules can be used with a protocol compliant scanner as part of control system
architecture. The modules’ built-in unmanaged 2-port Ethernet switch allows you to use the network topology
that meets your application needs. These topologies include the following:
star
daisy-chain
combination of star and daisy-chain
Star topology
Star topology allows you to connect mixed I/O modules or additional equipments. 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
You can create a daisy-chain topology by using the module’s embedded switch ports to connect a series
of up to 8 HarshIO eIP modules.
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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Combination of star and daisy-chain topology
Combining star and daisy-chain topology allows you to connect HarshIO eIP modules with mixed
HarshIO modules or additional equipments.

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Typical application
This diagram shows you an example of a typical application using in-cabinet PLC controlling HarshIO
eIP modules mount on various industrial systems.

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Quick Connect applications
The HarshIO eIP modules are designed to support the new Quick Connect feature according the
ODVA specifications which allow to power up, connect an EtherNet/IP scanner and start I/O cyclic data
exchange in less than 500 msec.
The Quick Connect feature is typically used in robotic application where some I/O devices are mounted
on a tool changer. The robot can disconnect and reconnect on the fly a new tool without stopping the
manufacturing process.
The diagram shows you an example of a robotic application using Quick Connect feature.
Quick Connect Architecture
When Quick Connect feature is used, the following recommendations should apply:
The Quick Connect device Ethernet switch ports must be configured with fixed speed to
100Mbps and full duplex enabled (auto negotiation is prohibited).
The Ethernet cable mounted on the robot must be connected to the ETH1 port (MDI port) of the
HarshIO eIP module. Quick Connect devices shall not use Auto-MDIX (detection of the required
cable connection type). This detection may take more time than the allowed Quick Connect
system connection time (see diagram below).
The maximum number of Quick Connect HarshIO eIP modules connected using daisy-chain
topology on the robot tool changer is recommended to be less or equal to 8. This limit can be
reduced depending of the Quick Connect performance supported by the EtherNet/IP controller.

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Enabling Quick Connect mode
The HarshIO eIP modules can be configured for Quick Connect mode according the 2 methods:
1. Set Byte 9, Bit 0 of the configuration assembly (see chapter I/O Data Mapping).
- a value of “0” automatically
odisables Quick Connect
osets ETH1 and ETH2 Ethernet ports to autonegociation and Auto-MDIX
- a value of “1” automatically
oenables Quick Connect
osets ETH1 port to 100 Full Duplex MDI
osets ETH2 port to 100 Full Duplex MDIX
2. Set Attribute 12 of CIP TCP/IP object (0xF5) using Explicit Messaging
- a value of “0” automatically
odisables Quick Connect
osets ETH1 and ETH2 Ethernet ports to Auto-MDIX
- a value of “1” automatically
oenables Quick Connect
osets ETH1 port to MDI
osets ETH2 port to MDIX
Remember: Don’t forget also to force the ETH1/ETH2 ports speed to 100 Full Duplex
by setting to 1 the Attribute 6 of CIP Ethernet Link object (0xF6).

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Caution: If method 2 is used, don’t forget to set to “0”the Configuration Assembly data
size (see chapter I/O Data Mapping) to avoid overwriting the Quick Connect Attribute
during the I/O connection with the EtherNet/IP scanner (Forward Open request).
Note: After each change of Quick Connect mode (means enabledisable), the HarshIO module stores
the new requested mode in its non-volatile memory. The module behaves in this mode until the next
modification.
Note: The modification of a Quick Connect mode is applied after the next power supply cycling of the
module or by sending a Reset command (CIP object 0x01, Instance 1 Service 5).

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4.Module Characteristics
Hardware characteristics
Type
16x INPUTS
16x OUTPUTS
Product Reference
TCDEI-8D0P-DYU-G (4-pin power version)
TCDEI-8D0P-D1U-G (5-pin power version)
TCDEI-80DP-DYU-G (4-pin power version)
TCDEI-80DP-D1U-G (5-pin power version)
Power
Power IN connector
Mini Change (7/8”), 4-pin or 5-pin, male, stainless steel, Maximum 8 A
Power OUT connector
Mini Change (7/8”), 4-pin or 5-pin, female, stainless steel, Maximum 8 A
Module & Input power (UB)
24 VDC, -15/+20% (protected against power crossing).
Warning, a voltage over 30 VDC will destroy the module
Operating current (UB)
68 mA
Output power (UL)
Not Applicable
24 VDC, -15/+20%
(protected against power crossing)
Operating current (UL)
Not Applicable
10 mA (without load)
Inputs
Channels
16 channels, 2 or 3-wire
Not Applicable
Connector
M12 Ultra-Lock, 5-pin, female, A-Coded,
stainless steel
Not Applicable
Input type
PNP, Sinking
Not Applicable
Input voltage
UB
Not Applicable
Sensor power supply
140 mA at 25°C
Not Applicable
Input channel voltage (“1”)
10V … 30V
Not Applicable
Input channel voltage (“0”)
-0.2V … 5V
Not Applicable
Input short circuit
protection (per port)
600mA
Not Applicable
Input filter
1 … 5 ms (5 ms by default)
Not Applicable
Outputs
Channels
Not Applicable
16 channels, 2-wire
Output voltage
Not Applicable
UL -1 VDC
Connector
Not Applicable
M12 Ultra-Lock, 5-pin, female, A-Coded,
stainless steel
Output type
Not Applicable
PNP, Sourcing
Output current
Not Applicable
2 A per channel
Maximum output current
Not Applicable
8.0 A at 25°C ; total for all outputs combined
Short circuit current (typical)
Not Applicable
up to 6.5 A
Switching frequency
Not Applicable
200 Hz

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Type
12x INPUTS + 4x OUTPUTS
8x INPUTS + 8x OUTPUTS
Product Reference
TCDEI-8B4P-DYU-G (4-pin power version)
TCDEI-8B4P-D1U-G (5-pin power version)
TCDEI-888P-DYU-G (4-pin power version)
TCDEI-888P-D1U-G (5-pin power version)
Power
Power IN connector
Mini Change (7/8”), 4-pin or 5-pin, male, stainless steel, Maximum 8 A
Power OUT connector
Mini Change (7/8”), 4-pin or 5-pin, female, stainless steel, Maximum 8 A
Module & Input power (UB)
24 VDC, -15/+20% (protected against power crossing)
Warning, a voltage over 30 VDC will destroy the module
Operating current (UB)
68 mA
Output power (UL)
24 VDC, -15/+20% (protected against power crossing)
Operating current (UL)
10 mA (without load)
Inputs
Channels
12 channels, 2 or 3-wire
8 channels, 2 or 3-wire
Connector
M12 Ultra-Lock, 5-pin, female, A-Coded, stainless steel
Input type
PNP, Sinking
Input voltage
UB
Sensor power supply
140 mA at 25°C
Input channel voltage (“1”)
10V … 30V
Input channel voltage (“0”)
-0.2V … 5V
Input short circuit
protection (per port)
600mA
Input filter
1 … 5 ms (5 ms by default)
Outputs
Channels
4 channels, 2-wire
8 channels, 2-wire
Output voltage
UL -1 VDC
Connector
M12 Ultra-Lock, 5-pin, female, A-Coded, stainless steel
Output type
PNP, Sourcing
Output current
2 A per channel
Maximum output current
8.0 A at 25°C ; total for all outputs combined
Short circuit current (typical)
up to 6.5 A
Switching frequency
200 Hz

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Fieldbus
Ethernet connectors
M12, 4-pin, female, D-Coded, stainless steel, shielded
IP setting
DHCP based on MAC (infinite lease), Static IP
Protocol
EtherNet/IP Adapter according specification Vol 1-3.9 (CIP) and Vol 2 –1.10 (EtherNet/IP)
Data access
Implicit messages for I/O data transfer
Implicit (I/O) connection
1x Exclusive Owner (EO) connection (with or without configuration data)
Up to 7 Listen Only (LO) or Input Only (IO) connections (with or without configuration data)
Explicit (EM) connection
Up to 8
Supported CIP Objects
0x01 –Identity object
0x02 –Message Router object
0x04 –Assembly object
o103: TO (Input process data)
o104: OT (Output process data)
o106: Configuration
o198: OT Heartbeat (Input Only)
o199: OT Heartbeat (Listen Only)
0x06 –Connection Manager object
0xF5 –TCP/IP Interface object
0xF6 –Ethernet Link object
Integrated Switch
2x ports integrated switch
Speed: 10/100Mbps
Auto negotiation
Auto crossing
Auto polarity
1x status Led / port
Storm Protection against network loop (Broadcast, Multicast and Unicast packets)
Daisy Chain (Ethernet)
Up to 8 HarshIO
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 (ACD supported)
Quick Connect
Yes (Class A)
ODVA conformance
Yes
Default IP setting:
IP address: DHCP
Subnet mask: DHCP
Gateway: DHCP
ETH1 port: Auto negotiation + Auto-MDI
ETH2 port: Auto negotiation + Auto-MDI
Quick Connect: Disabled
ACD Enabled