HIMA HIMax X-CI 24 51 User manual

d
X-CI 24 51
HIMax®
Counter Module
Manual

HI 801 189 E Rev. 4.01 (1203)
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 HIMA DVD and our website at http://www.hima.de and
http://www.hima.com.
© Copyright 2012, HIMA Paul Hildebrandt GmbH + Co KG
All rights reserved
Contact
HIMA contact details:
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
4.00 First Edition of the SILworX V4 Manual
4.01 Deleted: Redundant connector boards X X

X-CI 24 51 Table of Contents
HI 801 189 E Rev. 4.01 Page 3 of 64
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
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 X-CB 013 5X Connector Boards 20
3.6.2 Coding of X-CB 013 5X Connector Boards 21
3.6.3 Connector board with screw terminals 22
3.6.4 Terminal Assignment for Connector Boards with Screw Terminals 23
3.6.5 Connector Board 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 51
Page 4 of 64 HI 801 189 E Rev. 4.01
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 Counting Pulse Evaluation Type 36
4.4 Configuring the Counter Module in SILworX 38
4.4.1 Tab: Module 39
4.4.2 Tab: I/O Submodule CI24_51 40
4.4.3 Tab: I/O Submodule CI24_51: Channels 41
4.4.4 Submodule Status [DWORD] 44
4.4.5 Diagnostic Status [DWORD] 45
4.5 Connection Variants 46
4.5.1 Single-Channel Input Wiring 46
4.5.2 Single-Channel Input Wiring via X-FTA 002 48
4.5.3 Redundant Input Wiring 50
4.5.4 Measuring the Rotational Speed with Recognition of Rotation Direction 52
5Operation 54
5.1 Handling 54
5.2 Diagnosis 54
6Maintenance 55
6.1 Maintenance Measures 55
6.1.1 Loading the Operating System 55
7Decommissioning 56
8Transport 57
9Disposal 58
Appendix 60
Glossary 60
Index of Figures 61
Index of Tables 62
Index 63

X-CI 24 51 1 Introduction
HI 801 189 E Rev. 4.01 Page 5 of 64
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.

1 Introduction X-CI 24 51
Page 6 of 64 HI 801 189 E Rev. 4.01
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 51 1 Introduction
HI 801 189 E Rev. 4.01 Page 7 of 64
1.3.2 Operating Tips
Additional information is structured as presented in the following example:
i
The 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 51
Page 8 of 64 HI 801 189 E Rev. 4.01
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 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 51 2 Safety
HI 801 189 E Rev. 4.01 Page 9 of 64
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.

3 Product Description X-CI 24 51
Page 10 of 64 HI 801 189 E Rev. 4.01
3 Product Description
X-CI 24 51 is a NonSIL counter module intended for use in the programmable electronic system
(PES) HIMax.
The module can be inserted into any of the base plate slots with the exception of the slots
reserved for system bus modules. For more information, see System Manual (HI 801 001 E).
The 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 4.5.4.
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.
It can be operated with safety-related modules and other NonSIL modules within one base
plate. Safety-related and NonSIL modules may not be wired redundantly.
The module is interference-free, in particular, with respect to EMC, electrical safety,
communication to the X-SB and X-CPU modules, as well as the user program.
Module and connector boards are mechanically coded, see Chapter 3.6.1. Coding avoids
installation of improper I/O modules.
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 module does not perform any safety-related functions.
The parameters and status for this module must not be used for safety functions.
3.1.1 Reaction in the Event of a Fault
If a fault occurs, 0 is output as rotation speed and the user program retains its last valid process
value for the counter reading.
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
field termination assembly (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 51 3 Product Description
HI 801 189 E Rev. 4.01 Page 11 of 64
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 51
Page 12 of 64 HI 801 189 E Rev. 4.01
3.4 Structure
The counter module has 24 inputs that can measure frequencies in the range of 0...20 kHz for
control circuit devices Type 3 and in the range of 0...10 kHz for proximity switches. A short-
circuit-proof supply 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 4.2.2.
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 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 51 3 Product Description
HI 801 189 E Rev. 4.01 Page 13 of 64
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
Processsor 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 51
Page 14 of 64 HI 801 189 E Rev. 4.01
3.4.2 Indicators
The following figure shows the LED indicators for the counter module.
Figure 3: Indicators

X-CI 24 51 3 Product Description
HI 801 189 E Rev. 4.01 Page 15 of 64
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 51
Page 16 of 64 HI 801 189 E Rev. 4.01
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, e.g., open-circuit,
short-circuit, 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 51 3 Product Description
HI 801 189 E Rev. 4.01 Page 17 of 64
3.5 Product Data
General
Supply voltage 24 VDC, -15 %...+20 %, rP≤5 %, SELV, PELV
Current input 0.33 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. 0.9 kg
Table 7: Product Data
Figure 4: Views

3 Product Description X-CI 24 51
Page 18 of 64 HI 801 189 E Rev. 4.01
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
Proximity switch in accordance with EN 60947-5 1)
max. line resistance 50 Ω
Switch-on threshold L H 1.8 mA
Switch-off threshold H L 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 High > 10 V
Switch-off threshold High Low < 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 51 3 Product Description
HI 801 189 E Rev. 4.01 Page 19 of 64
Supply
Number of sources 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 15 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
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 51
Page 20 of 64 HI 801 189 E Rev. 4.01
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 51 Mono connector board with screw terminals
X-CB 013 53 Mono 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 X-CB 013 5X Connector Boards
I/O modules and connector boards are mechanically coded starting from hardware revision
AS00 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.