IDEC Blog

Illuminated emergency stop switches on teaching pendants: the future of industrial safety looks even brighter

IDEC continues to lead the way with bright ideas and safety innovations Illuminated models are options in the IDEC XA and XW emergency stop switch lineups (white body with a red light, or red body with a red light). The newest XA series illuminated switches are fitted on the IDEC HT3P and HT4P Safety Commander tablet holders with built-in safety functions. On Safety Commander tablet holders, the switch is positioned for easy access with either hand. It visually and physically stands out from the other optional buttons and switches available. IDEC’s illuminated e-stop switches maintain the space-saving design, reverse energy structure, lock/opening mechanisms, and environmental protection ratings that users expect. The combination of a teaching pendant with an illuminated emergency stop switch is still relatively rare. You can explore this possibility with IDEC products and solutions right now. Would you take a robot teaching pendant without an emergency stop button inside a safety fence where a robot is working? No, you wouldn’t. If the robot malfunctions or the operator is put in a dangerous situation, the emergency stop (e-stop) function can save their life and prevent damage and injury. Updates to safety standards also mean new ways to ensure compliance The specifications for e-stops to meet the requirements of ISO 13850:2015 are: “4.1.12: The emergency stop function shall be available and operational at all times . 4.3.6: The actuator of the emergency stop device shall be coloured RED . As far as a background exists behind the actuator and as far as it is practicable, the background shall be coloured YELLOW.” For the emergency stop function on portable operator control systems: “4.3.8: When emergency stop devices are installed on detachable or cableless operator control stations (e.g. pluggable portable teaching pendants), at least one emergency stop device shall be permanently available (e.g. in a fixed position) on the machine. In addition, at least one of the following measures shall be applied to avoid confusion between active and inactive emergency stop devices: device colour changing through illumination of the active emergency stop device; automatic (self-actuating) covering of inactive emergency stop devices; where this is not practicable, manually-applied covering may be used, provided that the cover remains attached to the operator control stations; provision of proper storage for detached or cableless operator control stations.” Up to now, emergency stop buttons haven’t used color illumination to indicate the active/inactive status. When users need to make it clear that the emergency stop function is inactive, they’ve often had to cover the switch or keep it stored in an appropriate location. IDEC’s XA/XW series of short body emergency stop switches offer a new type of illumination that complies with the requirements of ISO 13850:2015. They make it easy to determine the emergency stop function’s status based on the illumination: not lit up (off) when inactive, and lit up (on) when active. They also meet the requirements for an emergency stop, as they turn red when lit up (on). What makes this illuminated emergency stop switch, which complies with ISO 13850, a logical safety step? According to the requirements, the emergency stop function “shall be available and operational at all times” to meet safety standards. In addition, ISO 13850 includes a measure to indicate the active/inactive status of the switch by changing the color of the lighting. However, conventional e-stops with illumination are only partially lit up. The light may be harder to see as a result. If you want to use the color of the lighting to distinguish between active/inactive status, if the unit handle color is originally red then it is harder to determine whether the emergency stop is active or inactive. This means it is not easy to see if the unit is lit when indicating an active status. The switch handle on IDEC’s new XA/XW series illuminated e-stop is fully lit up whenever the function is active. If the button is not lit up in red, you immediately know it is not available or operational. The status can be confirmed from further away, from more angles, and in work environments with lower or minimum lighting. When mounted on a teaching pendant, an e-stop that lights up can support operators who are concentrating on other work processes. In other words, a teaching pendant equipped with IDEC's illuminated e-stop can clearly indicate a machine failure to you before an unexpected situation occurs. Teaching pendants and e-stops: long established as a reliable combination The e-stop has been an essential safety feature for industrial robot teaching pendants (also known as teach pendants) for many years. Even if the switch is rarely used, it’s important – and reassuring – for the operator to have one easily accessible at all times. This reliability has stayed true as teaching pendants have evolved: from wired devices to lightweight tablets with touchscreens and wireless communication. The importance of emergency stop switches hasn’t changed – that said, they have similarly moved with the times. As automated equipment continues to become smaller, the need for e-stop functionality is being met by a trend towards ever smaller solutions. The revised ISO 13850:2015 standards uphold the importance of the emergency stop switch, while incorporating market changes.

New product release: IDEC 4.3” HG1J IIoT-ready PCAP HMI for an intuitive touch interface

A robust and durable HMI with an expansive, clear display The projected capacitive (PCAP) HMI combines a compact size with powerful functionality – ideal for space-limited applications. Its design maximizes display area while keeping a minimal footprint. The PCAP display is water- and scratch-resistant, highly responsive, and resists false signals from dirt or water droplets on the surface. The durable glass top design ensures long life, with a backlight rated for 50,000 hours, and requires minimal maintenance. It passed a 1kg steel ball drop test from 60cm (with protective film) without damage, demonstrating resilience against rough handling, harsh conditions, and water sprays. The HMI also supports multi-touch with thin glove compatibility. The tempered glass prevents UV clouding for lasting clarity, and the touch panel's lack of moving parts minimizes wear. The HG1J and HG2J are built to last, with a 3-year warranty. They also have ratings for extreme temperatures (-20 to 55˚C), IP66 and IP67 for washdowns, IP66F and IP67F for oil resistance, and UL61010, UL Type 4X/13, and Class I Div 2 for safety. Both HMIs are ideal for diverse applications and environments. Empower your connectivity with IIoT technology In manufacturing systems, HMIs and other devices need to not only display data but also enable seamless data sharing across networks. The HG1J and HG2J offer IoT functionality, multiple connection ports, and support for open network protocols. With two USB-A ports, these HMIs support flash drives for data logging, recipes, program transfers, and dongles for speakers or Wi-Fi. The embedded Ethernet port provides easy access for remote maintenance, while Modbus TCP/IP, BACnet IP, EtherNet/IP, and MQTT protocols enable connectivity with other intelligent devices. These connections allow the HMIs to function as gateways between the work site and the cloud. Once connected, the HG1J and HG2J can read data from other system devices and send it to cloud storage. Built-in RS232C and RS422/485 serial communication ports with Modbus RTU support let the HG1J and HG2J communicate with other serial PLCs or devices, such as barcode readers and temperature controllers. Seamless remote monitoring and control with Wi-Fi enabled HMI solutions System-wide communication is crucial to keep production lines and processes running smoothly. However, not every device in a manufacturing system is always on site or connected by control panel wiring. Wireless connections help bridge the gaps between facilities and remote equipment. By plugging a Wi-Fi dongle into the USB port, users gain wireless connectivity. In addition, the web server function enables device information to be remotely viewed on a PC or tablet. Operators can now monitor and control equipment without needing to be physically present. Data and controls are also accessible via a dedicated app. Many communication options are available for users to create automation and IIoT solutions. They can easily incorporate multiple industrial protocols, the FTP protocol, remote monitoring and control, email/text messaging, Twitter/X, iOS and Android apps, and custom web pages. A comparison of the HG1J and HG2J HG1J : Compact 4.3-inch display TFT color LCD (16.77 million colors) 32 levels of brightness adjustment Operating temperature range: -20 to +55℃ Available in black and silver HG2J : Sleek 7.0-inch display TFT color LCD (65,536 colors) 48 levels of brightness adjustment Operating temperature range: -20 to +60℃ Available in black Smart manufacturing calls for intelligent devices. Industrial equipment operators rely on HMIs that work with them – not just for them – to boost efficiency and productivity. A critical aspect of interface usability is display 'visibility'. Thoughtful placement and clarity are essential for effective control panel layouts. Devices must also be resilient in harsh conditions, adaptable across diverse work environments, and dependable for unmanned operations. To meet these varied demands, IDEC introduced the HG2J PCAP touchscreen operator interface. Now, the more compact HG1J HMI joins the lineup. Learn more about the HG1J and HG2J here on the IDEC website Contact your local IDEC team for specific advice on HMIs and tailored solutions.

Maximize the efficiency and reliability of your automation system with the IDEC SX8R bus coupler module

4. Network compatibility and device communication Enjoy support for EtherNet/IP (adapter), Modbus TCP (server), and CC-Link IE Basic (slave station), the leading networks for industrial use. Using these communication protocols, you can build a remote I/O system with a PLC or controller. As the SX8R is compatible with multiple protocols, you can connect a controller (PLC) and a monitoring device (HMI) to the SX8R at the same time. (Note: simultaneous connection of EtherNet/IP and CC-Link IE Basic is not possible.) 2. High level of safety The SX8R bus coupler module and FC6A I/O modules are products that comply with PLC standards (IEC/EN 61131-2), have the CE/UKCA mark, and hold UL/cUL, UL 121201: Class 1 Div 2, and RCM certification. As such, they can be safely used in major global regions. Depending on the location, industry, and operating environment, factory equipment can be exposed to extreme temperatures. The SX8R bus coupler module and the FC6A I/O modules maintain reliable performance in hot and cold environments, with a wide operating temperature range from -25°C to +65°C. How the SX8R could simplify industrial automation and remote I/O systems Module configurations and I/O module setting parameters can be saved as project files for use in a future remote I/O system – a time-saving advantage during initial setup. Once the system is operational, you can use SX8R Configurator to carry out monitoring and diagnostics remotely. Information about each I/O module (on/off status for digital I/O modules, current values, set values and error information for analog I/O modules) can also be viewed remotely. If an error occurs, having data on the error type and a proposed solution can reduce the amount of system downtime. 5. Easy setup and intuitive operation SX8R Configurator is the dedicated settings software with the SX8R, offered as a free download from IDEC websites. It helps users configure the SX8R’s transmission settings and each module’s operational settings, and enables module status monitoring. The SX8R Configurator program feels intuitive – even for first-time users. Start by using the ‘drag and drop’ function to create a layout of your SX8R and I/O module system. You can then configure each module’s operation via the user-friendly menu options. What is the SX8R bus coupler module? We will explain the role of bus coupler modules in factory automation systems in terms of a remote I/O system. I/O modules form the system alongside the main controller, such as a PLC, and act as input/output interfaces for each control device (switches, lamps, sensors, etc.). I/O modules are either housed with the controller (local I/O), or in a different location to the controller and connected via network cables (remote I/O). Local I/O is also known as a centralized system, and remote I/O is also known as a decentralized system. Remote I/O systems are commonly used in a variety of industrial applications, including for automated production lines, food and packaging equipment, machine tools, and logistics. The control devices connected to the system may not all be in the same place – for example, on production lines or in logistics warehouses. Setting up a controller in each location would be inefficient and expensive. Connecting each control device to an I/O module using long cables would be complicated, take up space, and increase the risk of data transmission errors. To build a decentralized remote I/O system, the I/O modules by themselves aren’t enough. Local I/O modules connected to the controller can share data directly. Remote I/O modules send and receive data via a dedicated communication module with network protocol support. This is where the IDEC SX8R bus coupler module comes in. So that I/O modules can transmit data between connected control devices and the controller, the SX8R bus coupler module helps to compile, interpret, and send the control signals. The SX8R is made for factory automation systems that rely on stable communication between a central control system with a controller and the remote I/Os. 3. Simple, flexible installation Installing the SX8R is simple for 2 key reasons: its compact size and the use of push-in terminals. The SX8R can be mounted directly or on a DIN rail, so that it’s ideally positioned within your setup and takes up as little installation space as possible. Wiring time can be reduced by as much as 55% with push-in terminals, compared to wiring screw terminals. There’s no need to loosen and retighten screws with push-in terminals – or to use a screwdriver at all. Factory automation is intended to help manufacturing processes run more smoothly by nature. Automating manufacturing processes can increase work efficiency and productivity, raise workplace safety levels, mitigate labor shortages, and contribute to sustainable manufacturing activities. To help realize factory automation, an important link in the chain of many remote I/O systems used at manufacturing sites is a bus coupler module. IDEC offers the SX8R bus coupler module: a device that’s compatible with a wide variety of control signals and helps to save space, wiring time, and labor costs. 1. Modular design and scalability You can choose from a wide range of I/O modules, with the ability to expand to up to 15 modules. This allows for exceptional customization to meet diverse application needs. The SX8R supports up to 7 I/O modules, and by adding the expansion interface module, an additional 8 modules can be integrated. With a total of 15 modules, the system can handle up to 480 digital I/Os, 120 analog inputs, and 60 analog outputs. This expansion capability provides flexibility in building a remote I/O system tailored to the scale of any automation setup. The SX8R is compatible with over 40 IDEC FC6A MicroSmart PLC I/O modules, supporting a wide range of discrete and analog signals. Where does a remote I/O system fit into your factory automation plans? The SX8R bus coupler module has the compact design and convenience needed in industrial settings. IDEC’s remote I/O system solutions offer control device compatibility, network connectivity, and flexible expansion. IDEC offers the SX8R bus coupler module and the FC6A I/O modules globally. Read through the product catalog and explore your options here on the IDEC website. User-friendly features of the SX8R bus coupler module

New product release: IDEC FT1J controller with operator interface

Tempered glass for clarity, durability, and environmental protection Both the FT1J and FT2J models feature a projected capacitive (PCAP) reinforced glass touchscreen, offering a robust and modern alternative to traditional analog resistive touchscreens. PCAP glass panels remain relatively uncommon in operator interfaces, making this design choice a significant advantage for the FT1J and FT2J in terms of both physical and environmental durability. These units are designed to operate reliably across a wide temperature range of -20 to +55°C. In harsh environments, where the interface may be exposed to constant UV light, the reinforced glass prevents clouding, ensuring long-lasting clarity. Additionally, the glass top has an IP66F/IP67F rating, providing superior protection against water, oil, dirt, and dust – making both models ideal for use in challenging, messy, or wet environments. With no moving parts, the touch panel avoids mechanical wear over time, delivering consistent performance regardless of how hard it is pressed. In fact, the FT2J’s screen, equipped with a protective film, successfully passed a drop test involving a 1kg steel ball dropped from a height of 60 cm, demonstrating its toughness. This high level of external protection ensures the device's internal components continue to perform optimally, maximizing the overall reliability of the FT1J and FT2J in demanding applications. IoT connectivity, seamless integration and communication The FT1J’s compact design delivers powerful functionality with advanced IoT connectivity. At its core is a dual-CPU configuration, unlike similar products that rely on a single CPU for both HMI and control functions. By dedicating one CPU to HMI operations and the other to control tasks, the FT1J and FT2J achieve high-speed processing and rapid response times. The unit comes with up to 14 onboard I/O points, expandable to 22 I/O points to suit various application needs. Built-in analog inputs and outputs allow for seamless integration with complex control systems. Designed to handle advanced control functions, the FT1J includes PID control, Pulse Width Modulation (PWM), high-speed inputs, and script programming – offering the flexibility to address a wide range of automation challenges. For data logging, recipes, and program transfers, two USB-A ports support flash drives, and additional dongles enable features like speakers, Wi-Fi, and Bluetooth. The embedded Ethernet port allows easy access for remote maintenance and communication, while the unit supports multiple protocols – Modbus TCP/IP, BACnet IP, EtherNet/IP, and MQTT – for connectivity with other intelligent devices. Additionally, built-in RS232C and RS422/485 serial ports support Modbus RTU, enabling communication with serial PLCs or devices such as barcode readers and temperature controllers. All configuration for both the PLC and HMI is managed through IDEC’s intuitive WindOI-NV4 software, which offers a drag-and-drop interface and a comprehensive image library. Projects can be converted across different HMI sizes within seconds. Features such as script programming, PID loop control, PWM control, multilingual support, security settings, trend charts, data and alarm logs are fully integrated for both the PLC and HMI. With a unified program file that supports both, users can efficiently manage their automation projects. Which PLC + HMI to choose? A comparison of the FT1J and FT2J FT1J : Compact 4.3-inch display Approx. 1/2 the depth of a separate PLC and HMI (53.5mm) Up to 22 I/O points (analog and digital) TFT color LCD (16.77 million colors) 32 levels of brightness adjustment Weight: approx. 300g FT2J : Immersive 7.0-inch display Approx. 1/3 the depth of a separate PLC and HMI (35.3mm) Up to 30 I/O points (analog and digital) TFT color LCD (65,536 colors) 48 levels of brightness adjustment Weight: approx. 600g As Industry 4.0 continues to drive innovations in manufacturing, PLCs and HMIs in industrial settings must adapt to meet diverse user demands. Control is just one aspect. Interfaces must also save space, reduce energy consumption and costs, perform reliably in harsh environments, and provide the necessary connectivity for remote operation, monitoring, and maintenance. IDEC introduced the FT2J controller with an operator interface to help customers address these challenges. Now, the product line is expanding with the release of the FT1J PLC + HMI, offering an all-in-one automation solution in an even more compact design. Compare the IDEC FT1J and FT2J on the IDEC website To discover how the FT1J and FT2J controllers with operator interface could meet your specific needs, please get in touch with your local IDEC team. Sleek design that minimizes installation space and maximizes the display area Are industrial control panels shrinking? Some reports suggest this 'downsizing' trend is a noticeable outcome of Industry 4.0. More accurately, modern control panels are being engineered to save space. Optimized and intuitive layouts not only enhance operational efficiency, but also future-proof systems. The first step in creating a space-efficient control panel is streamlined device installation. The FT1J’s depth is nearly half that of a separate PLC and HMI, making it much easier to fit into tight spaces. Additionally, the detachable push-in terminal blocks simplify and accelerate wiring. Wherever the operator interface is placed on the panel, it must display information clearly without obstructing access to other controls. The FT2J, with its already compact 7.0-inch width, set the standard. The 4.3-inch FT1J display features 16 million colors and 32 levels of brightness adjustment, delivering vibrant visuals and customizable clarity for any environment. Both units provide ample display space to give operators a complete view of their data. The slim bezel maximizes the panel's surface area, allowing as much information as possible to be displayed on screen.

Simplifying control panel wiring: how push-in terminals enhance efficiency in industrial applications

A step-by-step guide to removing wires from a push-in terminal Step 1 : press and hold the pusher with a flat blade screwdriver. Step 2 : while holding down the pusher, pull out the wire. Again, it’s simple, and takes less time than loosening screws. On IDEC products with push-in terminals, the release tabs are yellow or orange to make them easier to find. They are essential for removal – pulling on a secured wire in a push-in terminal will add to the amount of force keeping it in place. How to install products with push-in terminals in your control panel Important safety note : make sure that electric power to all control panel devices is off before starting installation, wiring, inspection, maintenance and removal. Failure to do so may create a fire hazard or cause electrical shocks. All terminals need to be mounted securely on a suitable surface. That could be the back of a control panel switch, or on a DIN rail. For contact block mounting : IDEC contact blocks snap onto the back of compatible pushbuttons and indicator lights. Make sure that the locking ring is fastened before attaching the contact block. For DIN rail mounting : The DIN rail should always be horizontal. IDEC products designed to attached to DIN rails clamp or snap into place. IDEC products for control panels are designed to be compact, reducing the panel area and the amount of installation space needed behind it. They give you more room to create the optimum arrangement of terminals and wires. The more devices and switches that are installed on your control panel, the more wires you need to connect. The more wires you have, the more likely you are to need (and use) terminal blocks to keep them secure and organized. Terminal blocks act as ‘junctions’ for the wiring system, routing tens or hundreds of wires between input and output devices. They can be found behind control panels in many industrial applications (manufacturing, automotive, etc.) where complex electrical systems need to be installed quickly and safely. For industrial users, push-in terminals offer practical solutions Push-in terminal wiring efficiency makes a real difference during control panel wiring. Add on the safety, convenience, and space-saving benefits that push-in terminals provide, and the choice is clear. You can continue to expect frequent product innovations and functional safety developments from IDEC. The rise of push-in terminals for quick, efficient and tool-free wiring When wiring a terminal block with push-in technology, you might feel like you’re missing something: a screwdriver. With screw terminals, you need to loosen the screw, insert the wire, and retighten the screw. With spring clamp terminals, you need a tool to hold the clamp open until the wire is inserted. The extra work time needed to secure each wire soon adds up. With push-in terminals and wires with a crimped ferrule (or solid wires), you don’t need to use a screwdriver at all. Keeping at least one hand free during the wiring process can improve concentration and reduce reaction time if there is an issue. The risk of injury is low, thanks to the IP20 finger-safe protection rating IDEC push-in terminals hold. A step-by-step guide to push-in terminal wiring Step 1 : push the wire to the back of the wiring port. Step 2 : give the wire a light pull to confirm it’s connected properly. That’s all you need to do. Using this quick and simple process, time spent on wiring work could be shortened by as much as 55% (compared to wiring a screw terminal). You can see the difference in this socket wiring video: Three common types of terminal block Screw terminal : the traditional option. Spring clamp terminal : an evolution. Push-in terminal : the game-changer. Push-in terminals in their current form are a relatively new invention, but their popularity has rapidly grown. S3 (Safe, Simple, Smart) push-in connection technology enhances the appeal of many IDEC products, from automation devices to industrial components: FC6A PLC HG2J operator interface FT2J integrated PLC+HMI KW2D RFID reader HR2S safety relay module SJ/SU relay sockets HW switches and pilot lights CW flush switches and pilot lights The number and variety of IDEC products with push-in terminals reflects the widespread appeal, ease of use, and revolutionary nature of push-in wiring technology. Watch our timelapse wiring comparison video for control panel switches:

Assist Wheel Drive: the electric wheel that helps workers safely transport heavy payloads

Workers stay safer when using carts with electric powered wheels to transport heavy loads In many countries and industries, pushing and pulling are common causes of workplace injuries – especially back strain, sprains, and other MSDs. Pulling and pushing heavy payloads can result in other accidents, such as trips, slips and falls. Workers are at risk of injuring their fingers and hands – for example, if their hand is trapped between the trolley and a surface. Trolleys in motion can bump into a worker’s legs or run over their foot. A motorized trolley (with an electric wheel) that is easier to move and control can mitigate all of these risks. The Assist Wheel Drive controller has forward and reverse controls, and a stop button. The trolley’s speed, braking, and other settings can be easily adjusted using the dedicated ez-Config PC software. Improve workplace safety and employee well-being with Assist Wheel Drive Incorporating motorized equipment into manual handling processes can enhance health and safety for workers and reduce work-related injuries. The Assist Wheel Drive all-in-one system is compatible with the trolleys and carts that workers already use. The simple, integrated structure has universal compatibility and is simple to retrofit. Quick and easy access to trolleys powered by electric wheels could transform manual handling processes in your workplace. Set things in motion by learning more about Assist Wheel Drive now. Humans can focus on pushing the payload, not their physical limits When pushing, pulling, lifting or carrying items, the weight of the load is a key consideration. W orkplace health and safety standards in different countries vary. They agree on one thing – setting a fixed weight limit for manual handling is difficult. This is because the amount of weight that a person can safely lift, carry, push or pull depends on: their heights and weight their overall strength and frequency of their efforts their position, stance and posture the amount of friction on the floor how far away from the load they are how far the load needs to be transported, and how long it takes to move As a result, workplace load limits are often based on the amount of force needed to set a load in motion and keep it moving. ISO 11228-2 also defines acceptable force limits for manually handling loads. Electric power assistance via the wheels means less human force is needed to move a payload. Assist Wheel Drive helps workers by cutting the amount of physical effort required by as much as four fifths. Improved ergonomics reduce musculoskeletal injuries in the workplace ISO 11228-2 is an international standard for ergonomics. It contains guidelines and requirements for preventing work-related musculoskeletal disorders (MSDs). Manual handling puts workers at repeated risk of MSDs. As the body’s musculoskeletal system includes the bones, joints and muscles, MSDs include: muscle sprains and strains back injuries bone and joint injuries nerve damage chronic pain conditions Assist Wheel Drive is engineered to prevent musculoskeletal disorders in the workplace, by reducing manual efforts and repetitive strain. The potential positive impact of the system goes beyond individual employees’ health. Lower risk of injury reduces the number of working days lost to sick leave. Overall, workplace productivity could rise by as much as 50%. The ez-Wheel EW1A Assist Wheel Drive series is designed to improve productivity and efficiency, and to reduce physical stress on workers when transporting heavy loads. A high load capacity makes Assist Wheel Drive electric wheels suitable for transporting heavy parts and equipment. The EW1A-150 wheels can effortlessly move a maximum transferable load of 1,000kg. To help you imagine it, here’s what 1,000kg looks like in various industries: Automotive: between 3 and 7 petrol engines Food and packaging: between 5,000 and 6,000 average-sized apples Logistics: approx. 8,000 square meters of bubble wrap Construction: between 43 and 59 standard concrete blocks Manufacturing: almost 17 meters of rubber conveyor belt (if 1m wide, and 20mm thick) Assist Wheel Drive is fully compliant with ISO 11228-2 (ergonomics – manual handling part 2 – pushing and pulling). The system makes a real difference in work environments where heavy loads need to be transported safely and reliably.