Parts on this page: 18 items: 8 PLC modules (Mitsubishi, FATEK), 2 sensors (KEYENCE, Banner), 2 safety parts (OMRON, Schneider), 1 surge protector (P+F) and 5 relay / control parts (Crydom, OMRON, Schneider, P+F). They are used for building control cabinets and keeping breakdown spares for SMT lines, semiconductor equipment and automated warehouses.
What these parts do: in a control cabinet the PLC makes decisions, sensors report the line status, safety devices force a stop when there is danger, and relays and I/O modules pass signals between them. MRO purchasing rarely uses a single brand; a common mix is a Mitsubishi or FATEK PLC, KEYENCE sensors and OMRON or Schneider safety parts. Inverters, servo drives and SMC / FESTO pneumatic parts are on the “Inverters, servo drives and solenoid valves” page.
The 18 items
| Category | Brand | Model | Function / spec |
|---|---|---|---|
| PLC module (8) | Mitsubishi | Q12HCPU | CPU module, 4096 points / 124K steps, central processor for large automation systems |
| PLC module | Mitsubishi | AJ65SBT2B-64DA | Analog output (D/A) module, CC-Link |
| PLC module | Mitsubishi | FX2N-64MR | FX series main unit, 64 I/O points (32 in / 32 out), AC100-240V |
| PLC module | Mitsubishi | A1SJ71QC24N1-R2 | QC24N series serial communication module |
| PLC module | Mitsubishi | RJ61BT11 | CC-Link network module |
| PLC module | FATEK | FBS-20MCR2-AC | FBs series 20-point main unit, AC power |
| PLC module | FATEK | FBS-CM55 | 2-port RS485 communication expansion board |
| PLC module | FATEK | FBs-6AD | 6-channel analog input (A/D) module |
| Sensor (2) | KEYENCE | LR-TB5000 | Laser distance sensor, DC20-30V, time-of-flight |
| Sensor | Banner | T30UXIAQ8 | Ultrasonic sensor, DC10-30V |
| Safety (2) | OMRON | F3S-TGR-NSMC-21-05 | Non-contact safety door switch |
| Safety | Schneider | XPSUAK12AP | Safety relay DC24V, monitors emergency stop and safety door (ISO 13849 PLe) |
| Surge protection (1) | P+F | K-LB-2.30 | Signal circuit surge protection barrier |
| Relay / control (5) | Crydom | CY9007 | Solid-state relay (SSR), DC4-30V control → 660VAC × 25A |
| Relay / control | OMRON | H3BA-N8H | Timer relay AC110V × 30 s, timed 1ab + instantaneous 1ab |
| Relay / control | OMRON | CRT1-ID16 | 16-point input module |
| Relay / control | Schneider | ZB4BA1 | φ22 mm push button head, white |
| Relay / control | P+F | KCD2-SR-EX2 | Intrinsically safe switch amplifier (signal isolation, ATEX hazardous areas) |
Typical uses
- New control cabinet (line expansion): a new SMT line or semiconductor process station needs a PLC, sensors, safety parts and I/O in one go; the 18 items can be bought from one source in one shipment. Example: Mitsubishi Q12HCPU + FATEK FBs-20MCR2 + KEYENCE LR-TB5000.
- Upgrading old machines and integrating communication: moving from FX to Q series, adding an RS485 board (FBS-CM55) to a FATEK main unit, or connecting Mitsubishi RJ61BT11 to CC-Link, so older machines can be linked to the MES. Example: Mitsubishi RJ61BT11 + FATEK FBS-CM55.
- Raising the safety level (ISO 13849 PLd / PLe): when an audit or new rule asks for a higher safety level, a non-contact safety door switch (OMRON F3S-TGR) replaces a mechanical door switch, a Schneider XPSUAK12AP safety relay monitors the emergency stop and safety door, and ZB4BA1 is used for panel buttons.
- Signal isolation in hazardous areas (wet process / chemical): around wet process tanks and on chemical lines, an intrinsically safe switch amplifier (P+F KCD2-SR-EX2) isolates signals and limits energy to avoid sparks in hazardous areas; the P+F K-LB is a surge protector for signal circuits, a different function.
- Level and object detection: when the output error rate is high, add a LR-TB5000 laser to measure tray position and a T30 ultrasonic sensor to measure bin height, and connect them back to the existing PLC through an OMRON CRT1 input module.
Why a “PLC in the centre plus branches” layout
Each branch has different signals: sensors are analog 4-20 mA, servo drives use high-speed communication, and safety devices use dual-channel forced disconnection. Processing everything in the PLC keeps the decision logic in one place (read sensors → decide → drive actuators → monitor safety), so branches do not need direct links, the wiring stays simple and faults are easier to find.
Mixing brands: communication protocols of different brands may not match, so choose communication gateways with care. FATEK FBS-CM55 (RS485), Mitsubishi A1SJ71QC24N1-R2 (serial) and RJ61BT11 (CC-Link) on this page are communication modules that can serve as cross-brand interfaces.
ISO 13849 performance levels: reaching PLd and PLe
SMT lines, semiconductor equipment and automated warehouses are often audited for machine safety. ISO 13849 defines five performance levels, PLa to PLe; the higher the level, the stricter the requirements.
| Level | Meaning | Typical example (the required PLr comes from your risk assessment) | Key design |
|---|---|---|---|
| PLa / PLb | Low risk (reversible injury) | Mechanical hazards with minor, reversible injury | Single safety channel |
| PLc | Medium risk | Light industrial machines | Single channel + monitoring |
| PLd | High risk (injury may be irreversible) | SMT lines, CNC machine tools | Dual channel + validated safety components |
| PLe | Very high risk (fatal) | Semiconductor equipment, chemical processes | Dual channel + fault self-diagnosis + validated components |
Three design points for PLd / PLe:
- Dual-channel redundancy: two safety door switch signals go separately to the PLC safety input and the safety relay, so if one fails the other can still stop the machine.
- Validated safety components: OMRON F3S-TGR and the Schneider XPSU series have published validation data that can be referenced (other brands’ safety parts can be quoted).
- Extra signal isolation in hazardous areas: in Zone 1 / Zone 2 circuits, use an intrinsically safe isolator (for example P+F KCD2-SR-EX2) to avoid sparks; the P+F K-LB series is a surge protector, a different function.
Safety relay + emergency stop + inverter STO: most industrial inverters support STO (Safe Torque Off), which cuts the inverter’s torque output with two independent signals and reacts faster than opening the main contactor. Wiring in three steps:
- Connect the two normally open contact sets of the safety relay (Schneider XPSUAK12AP) to the inverter’s STO inputs.
- Connect the emergency stop button (such as Schneider XB4BS8442, not listed on this page, available on request) and the safety door switch (OMRON F3S-TGR) to the safety relay inputs.
- In hazardous areas, add an intrinsically safe switch amplifier (P+F KCD2-SR-EX2) for signal isolation.
Resulting sequence: emergency stop pressed → safety relay opens → inverter STO cuts torque → motor stops (usually within about 100 ms, depending on the model). STO cuts torque only, not main power, so the main switch still has to be opened by hand for maintenance.
Reaching a performance level requires an assessment of the whole system (including MTTFd, diagnostic coverage DC and common cause failure CCF); using validated components alone is not enough. Have it assessed by an independent assessment body or a safety engineering consultant (case by case).
Breakdown spares by machine criticality
The cost of a failed control cabinet part is tied directly to the value of one hour of downtime, so stock spares by machine criticality:
| Tier | Machines | Spares setup | Example spares |
|---|---|---|---|
| A | Critical machines that cannot stop 24/7 (semiconductor plants, chemical lines, non-stop lines) | One set each of PLC CPU, safety relay and drive | Q12HCPU + XPSUAK12AP (drives on the drive and pneumatics page) |
| B | General production machines | One core set (CPU) shared by 4–6 machines; sensors and short-life relays per machine | Shared FX2N-64MR + one SSR and laser sensor per machine |
| C | Non-critical or first-line replacement parts | For standard relays, buttons and terminal blocks, stock “yearly replacement × 1.5”; FATEK FBS-CM55 boards and CRT1 input modules fall here | H3BA-N8H timer relay / CRT1-ID16 / ZB4BA1 button head |
| D | Old models | For older series still in use (such as FX2N, A1S), keep 1–2 extra sets until the whole system is upgraded | FX2N-64MR, A1SJ71QC24N1-R2 |
Standard reference: ISO 13849-1:2023, Safety of machinery – Safety-related parts of control systems – Part 1, Ed. 4, International Organization for Standardization (ISO).
Common questions
What is the difference between the P+F KCD2-SR-EX2 and K-LB-2.30? KCD2-SR-EX2 is an intrinsically safe switch amplifier for signal isolation in hazardous areas; K-LB-2.30 is a surge protection barrier for signal circuits.
Does using an OMRON F3S-TGR or Schneider XPSUAK12AP make a machine PLe? No. The performance level comes from an assessment of the whole system (MTTFd, DC, CCF); validated components are one part of it.
Trademarks: Mitsubishi, OMRON, FATEK, KEYENCE, Schneider, Banner, Pepperl+Fuchs (P+F), Crydom, SMC, FESTO and the model names on this page are trademarks or model names of their owners, used here only to identify the products. JIAHON is not the authorized distributor of these brands in Taiwan.
Request a quote
Send the models and quantities; for the 18 items above you can request a quote for all of them together. Request a quote →