HIMA HIMax X-CI 24 01 User manual

d
X-CI 24 01
HIMax®
Counter Module
Manual

HI 801 113 E Rev. 4.00 (1117)
All HIMA products mentioned in this manual are protected by the HIMA trade-mark. Unless noted
otherwise, this also applies to other manufacturers and their respective products referred to herein.
All of the instructions and technical specifications in this manual have been written with great care and
effective quality assurance measures have been implemented to ensure their validity. For questions,
please contact HIMA directly. HIMA appreciates any suggestion on which information should be
included in the manual.
Equipment subject to change without notice. HIMA also reserves the right to modify the written material
without prior notice.
For further information, refer to the CD-ROM and our website http://www.hima.de and
http://www.hima.com.
© Copyright 2011, HIMA Paul Hildebrandt GmbH + Co KG
All rights reserved
Contact
HIMA Address
HIMA Paul Hildebrandt GmbH + Co KG
P.O. Box 1261
68777 Brühl, Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Type of Change
Revision
index
Revisions
technical editorial
3.00 New edition for SILworX V3 X X
4.00 Added: Chapter 4.3 and 4.4
New edition for SILworX V4
X X

X-CI 24 01 Table of Contents
HI 801 113 E Rev. 4.00 Page 3 of 68
Table of Contents
1Introduction ............................................................ 5
1.1 Structure and Use of this Manual......................................................................... 5
1.2 Target Audience..................................................................................................... 5
1.3 Formatting Conventions ....................................................................................... 6
1.3.1 Safety Notes ............................................................................................................ 6
1.3.2 Operating Tips ......................................................................................................... 7
2Safety...................................................................... 8
2.1 Intended Use .......................................................................................................... 8
2.1.1 Environmental Requirements................................................................................... 8
2.1.2 ESD Protective Measures........................................................................................ 8
2.2 Residual Risk ......................................................................................................... 9
2.3 Safety Precautions................................................................................................. 9
2.4 Emergency Information......................................................................................... 9
3Product Description .............................................. 10
3.1 Safety Function.................................................................................................... 10
3.1.1 Reaction in the Event of a Fault............................................................................. 10
3.2 Scope of Delivery................................................................................................. 10
3.3 Type Label ............................................................................................................ 11
3.4 Structure............................................................................................................... 12
3.4.1 Block Diagram........................................................................................................ 13
3.4.2 Indicators ............................................................................................................... 14
3.4.3 Module Status Indicators ....................................................................................... 15
3.4.4 System Bus Indicators ........................................................................................... 16
3.4.5 I/O Indicators.......................................................................................................... 16
3.5 Product Data......................................................................................................... 17
3.6 Connector Boards................................................................................................ 20
3.6.1 Mechanical Coding of Connector Boards .............................................................. 20
3.6.2 Coding of X-CB 013 Connector Boards ................................................................. 21
3.6.3 Connector Boards with Screw Terminals............................................................... 22
3.6.4 Terminal Assignment for Connector Boards with Screw Terminals....................... 23
3.6.5 Connector Boards with Cable Plug ........................................................................ 25
3.6.6 Pin Assignment for Connector Boards with Cable Plug......................................... 26
3.7 System Cable ....................................................................................................... 27
3.7.1 Cable Plug Coding................................................................................................. 28

Table of Contents X-CI 24 01
HI 801 113 E Rev. 4.00 Page 4 of 68
4Start-up................................................................. 29
4.1 Mounting ...............................................................................................................29
4.1.1 Wiring Inputs Not in Use.........................................................................................29
4.2 Mounting and Removing the Module..................................................................30
4.2.1 Mounting a Connector Board .................................................................................30
4.2.2 Using the Sensor Selection Plug to Define the Sensors ........................................32
4.2.3 Mounting and Removing the Module......................................................................33
4.3 Counter Module Sampling...................................................................................35
4.3.1 Type of Evaluation Count Pulses ...........................................................................36
4.4 Deviation Tab........................................................................................................38
4.5 Configuring the Counter Module in SILworX.....................................................39
4.5.1 Tab: Module ...........................................................................................................40
4.5.2 Tab: I/O Submodule CI24_01................................................................................. 41
4.5.3 Tab: I/O Submodule CI24_01: Channels................................................................42
4.5.4 Submodule Status [DWORD] ................................................................................. 46
4.5.5 Diagnostic Status [DWORD]...................................................................................47
4.6 Connection Variants.............................................................................................48
4.6.1 Single-Channel Input Wiring................................................................................... 48
4.6.2 Single-Channel Input Connection via X-FTA 002................................................... 50
4.6.3 Redundant Input Wiring..........................................................................................52
4.6.4 Measuring the Rotational Speed with Recognition of Rotation Direction ............... 56
5Operation .............................................................. 58
5.1 Handling................................................................................................................58
5.2 Diagnosis ..............................................................................................................58
6Maintenance.......................................................... 59
6.1 Maintenance Measures........................................................................................59
6.1.1 Loading the Operating System...............................................................................59
6.1.2 Proof Test...............................................................................................................59
7Decommissioning.................................................. 60
8Transport .............................................................. 61
9Disposal................................................................ 62
Appendix............................................................... 64
Glossary................................................................................................................64
Index of Figures....................................................................................................65
Index of Tables .....................................................................................................66
Index......................................................................................................................67

X-CI 24 01 1 Introduction
HI 801 113 E Rev. 4.00 Page 5 of 68
1 Introduction
The present manual describes the technical characteristics of the module and its use. It
provides information on how to install, start up and configure the module in SILworX.
1.1 Structure and Use of this Manual
The content of this manual is part of the hardware description of the HIMax programmable
electronic system.
This manual is organized in the following main chapters:
Introduction
Safety
Product Description
Start-up
Operation
Maintenance
Decommissioning
Transport
Disposal
Additionally, the following documents must be taken into account:
Name Content Document no.
HIMax
System manual
Hardware description of the
HIMax system
HI 801 001 E
HIMax
Safety manual
Safety functions of the HIMax
system
HI 801 003 E
HIMax
Communication manual
Description of communication
and protocols
HI 801 101 E
SILworX Online Help
(OLH)
Instructions on how to use
SILworX
-
First Steps Introduction to SILworX HI 801 103 E
Table 1: Additional Relevant Manuals
The latest manuals can be downloaded from the HIMA website at www.hima.com. The
revision index on the footer can be used to compare the current version of existing manuals
with the Internet edition.
1.2 Target Audience
This document addresses system planners, configuration engineers, programmers of
automation devices and personnel authorized to implement, operate and maintain the
devices and systems. Specialized knowledge of safety-related automation systems is
required.

1 Introduction X-CI 24 01
HI 801 113 E Rev. 4.00 Page 6 of 68
1.3 Formatting Conventions
To ensure improved readability and comprehensibility, the following fonts are used in this
document:
Bold: To highlight important parts
Names of buttons, menu functions and tabs that can be clicked and
used in SILworX.
Italics: System parameter and variables
Courier Literal user inputs
RUN Operating state are designated by capitals
Chapter 1.2.3 Cross references are hyperlinks even though they are not
particularly marked. When the cursor hovers over a hyperlink, it
changes its shape. Click the hyperlink to jump to the corresponding
position.
Safety notes and operating tips are particularly marked.
1.3.1 Safety Notes
The safety notes are represented as described below.
These notes must absolutely be observed to reduce the risk to a minimum. The content is
structured as follows:
Signal word: danger, warning, caution, notice
Type and source of danger
Consequences arising from the danger
Danger prevention
The signal words have the following meanings:
Danger indicates hazardous situation which, if not avoided, will result in death or serious
injury.
Warning indicates hazardous situation which, if not avoided, could result in death or
serious injury.
Warning indicates hazardous situation which, if not avoided, could result in minor or
modest injury.
Notice indicates a hazardous situation which, if not avoided, could result in property
damage.
NOTICE
Type and source of damage!
Damage prevention
SIGNAL WORD
Type and source of danger!
Consequences arising from the danger
Danger prevention

X-CI 24 01 1 Introduction
HI 801 113 E Rev. 4.00 Page 7 of 68
1.3.2 Operating Tips
Additional information is structured as presented in the following example:
iThe text corresponding to the additional information is located here.
Useful tips and tricks appear as follows:
TIP The tip text is located here.

2 Safety X-CI 24 01
HI 801 113 E Rev. 4.00 Page 8 of 68
2 Safety
All safety information, notes and instructions specified in this manual must be strictly
observed. The product may only be used if all guidelines and safety instructions are
adhered to.
This product is operated in accordance with SELV or PELV. No imminent danger results
from the module itself. The use in Ex-Zone is permitted if additional measures are taken.
2.1 Intended Use
HIMax components are designed for assembling safety-related controller systems.
When using the components in the HIMax system, comply with the following general
requirements
2.1.1 Environmental Requirements
Requirement type Range of values
Protection class Protection class III in accordance with IEC/EN 61131-2
Ambient temperature 0...+60 °C
Storage temperature -40...+85 °C
Pollution Pollution degree II in accordance with IEC/EN 61131-2
Altitude < 2000 m
Housing Standard: IP20
Supply voltage 24 VDC
Table 2: Environmental Requirements
Exposing the HIMax system to environmental conditions other than those specified in this
manual can cause the HIMax system to malfunction.
2.1.2 ESD Protective Measures
Only personnel with knowledge of ESD protective measures may modify or extend the
system or replace modules.
NOTE
Device damage due to electrostatic discharge!
When performing the work, make sure that the working area is free of static and
wear an ESD wrist strap.
If not used, ensure that the device is protected from electrostatic discharge, e.g.,
by storing it in its packaging.

X-CI 24 01 2 Safety
HI 801 113 E Rev. 4.00 Page 9 of 68
2.2 Residual Risk
No imminent danger results from a HIMax module itself.
Residual risk may result from:
Faults in the engineering
Faults in the user program
Faults in the wiring
2.3 Safety Precautions
Observe all local safety requirements and use the protective equipment required on site.
2.4 Emergency Information
A HIMax controller is a part of the safety equipment of a system. If the controller fails, the
system adopts the safe state.
In case of emergency, no action that may prevent the HIMax systems from operating safely
is permitted.

3 Product Description X-CI 24 01
HI 801 113 E Rev. 4.00 Page 10 of 68
3 Product Description
The X-CI 24 01 counter module is intended for use in the programmable electronic system
(PES) HIMax.
The counter module can be inserted in any of the base plate slots with the exception of the
slots reserved for system bus modules. For more information, refer to the System Manual
(HI 801 001 E).
The counter module is used to count the pulses, to measure the frequency and the
rotational speed and, if defined, to recognize the rotation direction. Two channels are
required to use the recognition of rotation direction function, see Chapter 4.6.4.
Proximity switches in accordance with EN 60947-5-6 (NAMUR) or control circuit devices of
type 3 in accordance with EN 61131-2 can be connected to the counter module. Proximity
switches and control circuit devices may not be operated simultaneously.
The module has been certified by the TÜV for safety-related applications up to SIL 3
(IEC 61508, IEC 61511 and IEC 62061), Cat. 4 (EN 954-1) and PL e (EN ISO 13849-1).
Refer to the HIMax Safety Manual (HI 801 003 E) for more information on the standards
used to test and certify the modules and the HIMax system.
3.1 Safety Function
The counter module samples the switching operations of the connected sensors with
safety-related accuracy (1 % if the frequency is measured, ± 1 pulse if the pulse is
measured) .
The safety function is performed in accordance with SIL 3.
3.1.1 Reaction in the Event of a Fault
If a fault occurs, the counter module enters the safe state. The rotation speed is set to 0.
The user program retains its last valid process value for the counter readings.
The module activates the Error LED on the front plate.
3.2 Scope of Delivery
The counter module must be installed on a suitable connector board to be able to operate.
If a FTA is used, a system cable is required to connect the connector board to the FTA.
Connector boards, sensor selection plug, system cables and FTAs are not included within
the module's scope of delivery.
The various connector boards are described in Chapter 3.6, the system cables in Chapter
3.7. The FTAs are described in separated manuals.

X-CI 24 01 3 Product Description
HI 801 113 E Rev. 4.00 Page 11 of 68
3.3 Type Label
The type label specifies the following important details:
Product name
Mark of conformity
Bar code (2D or 1D code)
Part number (Part-No.)
Hardware revision index (HW Rev.)
Software revision index (SW Rev.)
Operating voltage (Power)
Ex specifications (if applicable)
Production year (Prod-Year:)
Figure 1: Sample Type Label

3 Product Description X-CI 24 01
HI 801 113 E Rev. 4.00 Page 12 of 68
3.4 Structure
The counter module has 24 inputs that can measure frequencies in the range of 0...20 kHz
for control circuit devices and in the range of 0...10 kHz for proximity switches. A short-
circuit-proof transmitter supply monitoring overvoltage and undervoltage, is assigned to
each input.
The 24 inputs of the counter module can either be configured for proximity switches or for
control circuit devices. Which configuration should be used is defined by plugging in the
sensor selection plug to the rear side of the connector board in use, see Chapter 4.2.1.
The counter module maintains a deviation tab for each channel, see Chapter 4.4.
If proximity switches are used, the switching thresholds for open-circuits (OC) and short-
circuits (SC) are preset in accordance with EN 60947-5-6 (NAMUR). Short-circuit (SC) and
open-circuit (OC) monitoring is only allowed if the Proximity Switch setting is used.
The safety-related 1oo2 processor system for the I/O module controls and monitors the I/O
level. The data and states of the I/O module are made available to the processor modules
via the redundant system bus. The system bus has a redundant structure for reasons of
availability. Redundancy is only ensured if both system bus modules are inserted in the
base plates and configured in SILworX.
The module is equipped with LEDs to indicate the status of the counter outputs, see
Chapter 3.4.2.

X-CI 24 01 3 Product Description
HI 801 113 E Rev. 4.00 Page 13 of 68
3.4.1 Block Diagram
The following block diagram illustrates the structure of the counter module.
Field Zone: Proximity Switches, Control
Circuit Devices
Sensor Selection Plug
Counter
Safety-Related Processor System
System Busses
Figure 2: Block Diagram
iSensor Selection Plug
The sensor selection plug is drawn multiple times in the block diagram ( ). This is only
done to better represent the individual wirings!

3 Product Description X-CI 24 01
HI 801 113 E Rev. 4.00 Page 14 of 68
3.4.2 Indicators
The following figure shows the LED indicators for the counter module.
Figure 3: Indicators

X-CI 24 01 3 Product Description
HI 801 113 E Rev. 4.00 Page 15 of 68
The LEDs indicate the operating state of the counter module.
The LEDs on the counter module are divided into three groups:
Module status indicators (Run, Error, Stop, Init)
System bus indicators (A, B)
I/O indicators (CI 1...24, Field)
When the supply voltage is switched on, a LED test is performed and all LEDs briefly flash
simultaneously.
Definition of Blinking Frequencies
The following table defines the blinking frequencies of the LEDs:
Name Blinking Frequencies
Blinking1 Long (approx. 600 ms) on, long (approx. 600 ms) off
Blinking2 Short (approx. 200 ms) on, short (approx. 200 ms) off, short (approx. 200
ms) on, long (approx. 600 ms) off
Blinking-x Ethernet communication: Flashing in sync with data transfer
Table 3: Blinking Frequencies of LEDs
3.4.3 Module Status Indicators
These LEDs are located on the front plate, on the upper part of the module.
LED Color Status Description
On Module in RUN, normal operation
Blinking1 Module state:
STOP/OS_DOWNLOAD or
OPERATE (only with processor modules)
Run Green
Off Module not in RUN,
observe the other status LEDs
On/Blinking1 Internal module faults detected by self-tests, e.g.,
hardware, software or voltage supply.
Fault while loading the operating system
Error Red
Off Normal operation
On Module state:
STOP / VALID CONFIGURATION
Blinking1 Module state:
STOP / INVALID CONFIGURATION or
STOP / OS_DOWNLOAD
Stop Yellow
Off Module not in STOP, observe the other status LEDs
On Module state: INIT, observe the other status LEDs
Blinking1 Module state: LOCKED, observe to the other status
LEDs
Init Yellow
Off Module state: neither INIT nor LOCKED, observe
the other status LEDs
Table 4: Module Status Indicators

3 Product Description X-CI 24 01
HI 801 113 E Rev. 4.00 Page 16 of 68
3.4.4 System Bus Indicators
The system bus LEDs are labeled Sys Bus.
LED Color Status Description
On Physical and logical connection to the system bus
module in slot 1.
Green
Blinking1 No physical connection to the system bus module in
slot 1.
A
Yellow Blinking1
The physical connection to the system bus module
in slot 1 has been established.
No connection to a (redundant) processor module
running in system operation.
On Physical and logical connection to the system bus
module in slot 2.
Green
Blinking1 No physical connection to the system bus module in
slot 2.
B
Yellow Blinking1
The physical connection to the system bus module
in slot 2 has been established.
No connection to a (redundant) processor module
running in system operation.
A+B Off Off Neither physical nor logical connection to the
system bus modules in slot 1 and slot 2.
Table 5: System Bus Indicators
3.4.5 I/O Indicators
The LEDs of the I/O indicators are labeled Channel.
LED Color Status Description
On Frequency < 20 Hz at high level
Frequency > 20 Hz: No distinction between high and low
level is made for the LED.
Blinking2 Channel fault
Channel
1...24
Yellow
Off Frequency < 20 Hz at low level
Channel not configured.
Blinking2 Field fault on at least one channel or supply (open-circuit,
short-circuit, over-current, etc.)
Field Red
Off No field fault displayed!
Table 6: I/O Indicators
iConsequences on the Channel LED during two-phase operation and fault in one of
the channels of a channel pair!
0 Hz (default value) is displayed for the Rot. Speed (scaled) [REAL] process value. The
Channel LED for the faulty channel adopts the Blinking2 status and the faulty-free channel
reports the input signal state. With frequencies of > 20 Hz, the Channel LED cannot be
refreshed whenever the state changes.

X-CI 24 01 3 Product Description
HI 801 113 E Rev. 4.00 Page 17 of 68
3.5 Product Data
General
Supply voltage 24 VDC, -15 %...+20 %, rP≤5 %, SELV, PELV
Current input 0.7 A at 24 VDC without load
Current input for 24 V per channel and
high level
Proximity switch: typ. 1 mA, max. 10 mA
Control Circuit Device of Type 3:
typ. 5.5 mA, max. 30 mA
Operating temperature 0...+60 °C
Storage temperature -40...+85 °C
Humidity max. 95 % relative humidity, non-condensing
Type of protection IP20
Dimensions (H x W x D) in mm 310 x 29.2 x 230
Weight approx. 1.2 kg
Table 7: Product Data
Figure 4: Views

3 Product Description X-CI 24 01
HI 801 113 E Rev. 4.00 Page 18 of 68
Counter module inputs
Number of inputs (number of
channels)
24 with common ground CI-
(electrically isolated from the system bus).
Number of channel pairs
(Recognition of rotation direction)
12,
Channel pair 1 = CI01 and CI02
Channel pair 2 = CI03 and CI04
...
Channel pair 12 = CI23 and CI24
Sensors
(Selection performed using the sensor
selection plug)
Proximity switches in accordance with
EN 60947-5-6 (NAMUR), wired contacts or
Control circuit devices of type 3 in accordance
with EN 61131-2, power supplies.
Count frequency 0...10 kHz for proximity switches
0...20 kHz for control circuit devices of type 3
0...10 kHz for control circuit devices of type 3 and
evaluation type 2 phases / 4 edges
Resolution 0.1 Hz
Counter resolution 32-bit
Pulse width in one-phase operation min. 16.66 µs at 20 kHz
min. 33.33 µs at 10 kHz
Minimum edge distance between two
phases during two-phase operation
6 µs
Accuracy of pulse count ± 1 pulse
Accuracy of frequency and rotational speed measurement
- 1 phase, 1 edge
- 1 phase, 2 edges
- 2 phases, 1 edge
- 2 phases, 2 edges
- 2 phases, 4 edges, fmax = 10 kHz
±1 Hz
±15 Hz, with symmetric input signal
±1 Hz
±15 Hz, with symmetric input signals
±20 Hz, with symmetric input signals
Safety-related accuracy for frequency
and rotational speed measurement
±1 % of final value
Proximity switch in accordance with EN 60947-5 1)
max. line resistance 50 Ω
Switch-on threshold L ÆH 1.8 mA
Switch-off threshold H ÆL 1.4 mA
Open-circuit < 0.2 mA
Short-circuit > 6.5 mA
Control circuit devices in accordance
with EN 61131-2
Wire length 1000 m
Switch-on threshold Low ÆHigh > 10 V
Switch-off threshold High ÆLow < 8 V
1) The values of the proximity switch must be consistent with the defined values.
Table 8: Specifications for the Counter Inputs

X-CI 24 01 3 Product Description
HI 801 113 E Rev. 4.00 Page 19 of 68
Supply
Number of supplies 24
Output voltage
(depending on the sensors)
8.2 VDC ± 10 %, proximity switch
24 VDC -15 %...+20 %, control circuit device of
type 3
Max. output current for each supply 25 mA
Nominal short-circuit current, per
channel
(sensor short-circuit)
8.2 mA at 8.2 V, proximity switch
5.45 mA at 24 V, control circuit devices of type 3
Supply monitoring The counter module monitors the supplies for
overvoltage and undervoltage.
If the Supply used parameter is activated, a
supply error results in a channel fault (Channel
OK = FALSE)
Assignment of the supply outputs
For supplying, the voltage output assigned to the input must be used.
S01+…S24+ CI1+...CI24+
Table 9: Product Data for Supplies

3 Product Description X-CI 24 01
HI 801 113 E Rev. 4.00 Page 20 of 68
3.6 Connector Boards
A connector board connects the counter module to the field zone. Module and connector
board form together a functional unit. Insert the connector board into the appropriate slot
prior to mounting the module.
The sensor selection plug is located on the rear side of the connector boards and is used to
select the type of sensor for the module (proximity switch or control circuit device of type 3).
The sensor selection plug are included within the scope of delivery of the connector boards.
The following connector boards are available for the counter module:
Connector board Description
X-CB 013 01 Connector board with screw terminals
X-CB 013 02 Redundant connector board with screw terminals
X-CB 013 03 Connector board with cable plug
X-CB 013 04 Redundant connector board with cable plug
Sensor selection plug
X-SS CB 01 Sensor selection plug (Standard)
X-SS CB 02 Sensor selection plug of type 5
Table 10: Available Connector Boards
3.6.1 Mechanical Coding of Connector Boards
I/O modules and connector boards are mechanically coded starting from hardware revision
AS10 to prevent them from being equipped with improper I/O modules. Coding avoids
installation of improper I/O modules, thus preventing negative effects on redundant
modules and field zone. A part from that, improper equipment has no effect on the HIMax
system since only I/O modules that are correctly configured in SILworX enter the RUN
state.
I/O modules and the corresponding connector boards have a mechanical coding in form of
wedges. The coding wedges in the female connector of the connector board match with the
male connector recesses of the I/O module plug, see Figure 5.
Coded I/O modules can only be plugged in to the corresponding connector boards.