HONEYWELL XS824-25

Description

Product Description

The HONEYWELL XS824-25 is a highly versatile, stand-alone safety programmable logic controller (safety PLC) belonging to the SmartOne series, designed specifically for implementing safety instrumented systems (SIS) and critical control functions. This compact unit integrates 24 digital inputs and 4 digital outputs, combining safety and standard control logic in a single device to protect personnel and machinery. Engineered for simple yet robust safety applications, the HONEYWELL XS824-25 allows for the direct connection of emergency stops, safety gates, light curtains, and other safety sensors to monitor for faults and execute predefined safety reactions, such as halting a dangerous machine motion. Its user-friendly programming software enables the configuration of safety logic, diagnostics, and even basic standard control sequences without requiring complex safety certification expertise. For machine builders and system integrators needing a reliable, all-in-one safety controller solution, the HONEYWELL XS824-25 provides certified performance. The deployment of the HONEYWELL XS824-25 is a strategic choice for achieving compliance with international safety standards like ISO 13849 and IEC 62061.

Product Parameters

• Device Type: Compact Safety PLC (Programmable Safety System).
• Safety Standard Certification: Typically certified for Performance Level d (PLd) and Safety Integrity Level 2 (SIL 2), suitable for a wide range of safety functions.
• Inputs: 24 digital safety inputs (sourcing or sinking configurable) for connecting devices like E-Stop buttons, safety switches, and interlock sensors.
• Outputs: 4 solid-state safety outputs (typically PNP) for controlling safety relays, contactors, or solenoid locks.
• Programming: Configured using dedicated software (e.g., Honeywell SmartOne Configuration Studio) via a USB or serial connection.
• Diagnostics: Extensive built-in diagnostics for monitoring device health, input circuit status, and output loads.
• Power Supply: Operates on 24V DC nominal supply voltage.
• Enclosure Rating: Designed for mounting in an industrial control cabinet (IP20).

Advantages and Features

• All-in-One Simplicity: Combines safety logic solver, I/O, and power supply interface into one compact device, reducing panel space and wiring complexity compared to traditional safety relay setups.
• Flexible Logic & Diagnostics: Offers far greater flexibility than hard-wired relay logic, allowing for complex safety functions, muting, and zone control, all with extensive diagnostic reporting for easier troubleshooting.
• User-Friendly Configuration: Software-based configuration uses function block diagrams or ladder logic tailored for safety, making it accessible for control engineers without specialized safety language training.
• Cost-Effective Safety: For applications with multiple safety functions, the HONEYWELL XS824-25 is often more cost-effective than implementing a network of individual safety relays.
• Integrated Standard Control: Capable of handling basic standard (non-safety) control tasks alongside safety functions, potentially eliminating the need for a separate small standard PLC in simple machines.

Application Cases in Application Fields

• Packaging Machinery: Monitoring multiple access doors, an emergency stop circuit, and a robotic cell light curtain to ensure safe operation of conveyors and sealing heads.
• Press Brake / Metal Forming: Implementing a two-hand control system and presence sensing to safeguard the operator during the bending cycle.
• Automated Assembly Line: Providing safety interlocks for guarding around robots and automating zone-based safety for material handling carts.
• Palletizing System: Integrating safety gates and E-stops around a palletizer and using muting functions to allow safe pallet entry/exit during automatic operation.

Comparisons with Competing Products

Competing products in this niche include compact safety controllers from Siemens (SIMATIC ET 200SP F-CPU), Pilz (PNOZmulti), and Sick (Flexi Soft). Compared to modular safety relay systems (like those from Pilz or Banner), the HONEYWELL XS824-25 offers superior flexibility and diagnostic depth in a similarly compact footprint. Versus larger, full-scale safety PLCs (e.g., Rockwell Allen-Bradley GuardLogix), the HONEYWELL XS824-25 is simpler and more cost-effective for small to medium applications but has less I/O expansion capability. Its key advantage is its targeted design for the mid-range market, balancing certified safety performance with notable ease of use. For integrators looking for a straightforward, software-configured safety controller for a defined number of I/O points, the HONEYWELL XS824-25 presents a strong, integrated alternative.

Selection Suggestions and Precautions

1. Safety Performance Validation: Always conduct a risk assessment to determine the required Performance Level (PL) or Safety Integrity Level (SIL). Verify that the certified capabilities of the HONEYWELL XS824-25 (e.g., PLd, SIL 2) meet or exceed the requirements of your specific safety functions.
2. I/O Count and Type: Ensure the 24-input / 4-output configuration is sufficient for your application, including any future modifications. This device is typically not expandable with remote I/O.
3. Software Requirement: Account for the need to purchase and use the dedicated Honeywell configuration software for programming and commissioning the safety logic.
4. Wiring and Documentation: Safety system wiring must be performed to relevant standards (e.g., IEC 60204-1). Maintain meticulous documentation of the safety program, validation tests, and as-built wiring diagrams.
5. Validation and Testing: The complete safety function, including all sensors, the HONEYWELL XS824-25 logic, and final elements (contactors), must be properly validated and tested according to safety lifecycle standards before commissioning and at regular intervals thereafter.

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