HIMA HIMatrix CIO 2/4 01 User manual

HIMatrix
Safety-Related Controller
CIO 2/4 01 Manual
HIMA Paul Hildebrandt GmbH + Co KG
Industrial Automation
Rev. 2.00 HI 800 199 E

HI 800 199 E Rev. 2.00 (1334)
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.
HIMax®, HIMatrix®, SILworX®, XMR®and FlexSILon®are registered trademarks of HIMA Paul Hildebrandt
GmbH + Co KG.
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 2013, 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
1.00 Added: Configuration with SILworX X X
2.00 Added: CIO 2/4 014, SIL 4 certified according to EN 50126,
EN 50128 and EN 50129, Chapter 4.1.4 X X

CIO 2/4 01 Table of Contents
HI 800 199 E Rev. 2.00 Page 3 of 40
Table of Contents
1Introduction 5
1.1 Structure and Use of this Manual 5
1.2 Target Audience 6
1.3 Formatting Conventions 7
1.3.1 Safety Notes 7
1.3.2 Operating Tips 8
2Safety 9
2.1 Intended Use 9
2.1.1 Environmental Requirements 9
2.1.2 ESD Protective Measures 9
2.2 Residual Risk 10
2.3 Safety Precautions 10
2.4 Emergency Information 10
3Product Description 11
3.1 Safety Function 11
3.1.1 Safety-Related Outputs 11
3.1.1.1 Reaction in the Event of a Fault 11
3.1.2 Safety-Related Counters 11
3.1.2.1 Reaction in the Event of a Fault 12
3.2 Equipment, Scope of Delivery 12
3.3 Type Label 13
3.4 Assembly 14
3.4.1 Block Diagram 14
3.4.2 Front View 15
3.4.3 Module Indicators 16
3.4.4 I/O LEDs 16
3.4.5 Mode of Operation of the Counters 16
3.4.5.1 Counter Function 1 (Depending on the Count Direction Input Signal) 16
3.4.5.2 Counter Function 2 (Irrespective of the Count Direction Input Signal) 17
3.4.5.3 Decoder Operation with Attached Rotary Transducer 17
3.4.5.4 Comparing the Codes Used 18
3.5 Product Data CIO 2/4 01 18
3.5.1 Product Data CIO 2/4 014 19
4Start-up 20
4.1 Installation and Mounting 20
4.1.1 Mounting and Removing the Modules 20
4.1.2 Connecting the Counters 20
4.1.3 Connecting the Digital Outputs 21
4.1.4 Cable Plugs 22
4.1.5 Mounting the CIO 2/4 01 in Zone 2 23

Table of Contents CIO 2/4 01
Page 4 of 40 HI 800 199 E Rev. 2.00
4.2 Configuration 24
4.2.1 Module Slots 24
4.3 Configuration with SILworX 24
4.3.1 Parameters and Error Codes for the Inputs and Outputs 25
4.3.2 Counter and Outputs CIO 2/4 01 25
4.3.2.1 Tab Module 25
4.3.2.2 Tab CIO 2/4 01_1: Channels 27
4.4 Configuration with ELOP II Factory 27
4.4.1 Configuring the Inputs and Outputs 27
4.4.2 Signals and Error Codes for the Inputs and Outputs 27
4.4.3 CIO 2/4 01 Counter 27
4.4.4 Digital Outputs for CIO 2/4 01 29
5Operation 30
5.1 Handling 30
5.2 Diagnosis 30
6Maintenance 31
6.1 Faults 31
6.2 Maintenance Measures 31
6.2.1 Loading the Operating System 31
6.2.2 Proof Test 31
7Decommissioning 32
8Transport 33
9Disposal 34
Appendix 35
Glossary 35
Index of Figures 36
Index of Tables 37
Index 38

CIO 2/4 01 1 Introduction
HI 800 199 E Rev. 2.00 Page 5 of 40
1 Introduction
This manual describes the technical characteristics of the module and its use. It provides
information on how to install, start up and configure the module.
1.1 Structure and Use of this Manual
The content of this manual is part of the hardware description of the HIMatrix programmable
electronic system.
This manual is organized in the following main chapters:
Introduction
Safety
Product Description
Start-up
Operation
Maintenance
Decommissioning
Transport
Disposal
The HIMatrix F60 is available for the programming tools SILworX and ELOP II Factory. Which
programming tool can be used, depends on the processor operating system of the HIMatrix
F60, refer to the following table:
Programming tool Processor operating system Communication operating system
SILworX CPU OS V7 and higher COM OS V12 and higher
ELOP II Factory CPU OS up to V6.x COM OS up to V11.x
Table 1: Programming Tools for HIMatrix F60
In the manual, the differences are specified by using:
Separated chapters
Tables differentiating among the versions
iProjects created with ELOP II Factory cannot be edited with SILworX, and vice versa!
iThe manual usually refers to the plug-in cards of the modular controller F60 as modules.
Modules is also the term used in SILworX.

1 Introduction CIO 2/4 01
Page 6 of 40 HI 800 199 E Rev. 2.00
Additionally, the following documents must be taken into account:
Name Content Document number
HIMatrix System Manual
Compact Systems Hardware description of the HIMatrix compact systems HI 800 141 E
HIMatrix System Manual
Modular System F60 Hardware description of the HIMatrix modular system HI 800 191 E
HIMatrix Safety Manual Safety functions of the HIMatrix system HI 800 023 E
HIMatrix Safety Manual for
Railway Applications Safety functions of the HIMatrix system using the HIMatrix in railway
applications
HI 800 437 E
SILworX Online Help Instructions on how to use SILworX -
ELOP II Factory
Online Help Instructions on how to use ELOP II Factory, Ethernet IP protocol -
SILworX First Steps Introduction to SILworX using the
HIMax system as an example HI 801 103 E
ELOP II Factory First Steps Introduction to ELOP II Factory HI 800 006 E
Table 2: Additional Relevant Documents
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 modules
and systems. Specialized knowledge of safety-related automation systems is required.

CIO 2/4 01 1 Introduction
HI 800 199 E Rev. 2.00 Page 7 of 40
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 the programming tool.
Italics For parameters and system 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: warning, caution, notice
Type and source of risk
Consequences arising from non-observance
Risk prevention
The signal words have the following meanings:
Warning indicates hazardous situation which, if not avoided, could result in death or serious
injury.
Caution 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.
NOTE
Type and source of damage!
Damage prevention
SIGNAL WORD
Type and source of risk!
Consequences arising from non-observance
Risk prevention

1 Introduction CIO 2/4 01
Page 8 of 40 HI 800 199 E Rev. 2.00
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.

CIO 2/4 01 2 Safety
HI 800 199 E Rev. 2.00 Page 9 of 40
2 Safety
All safety information, notes and instructions specified in this document must be strictly
observed. The product may only be used if all guidelines and safety instructions are adhered to.
This product is operated with SELV or PELV. No imminent risk results from the product itself.
The use in Ex-Zone is permitted if additional measures are taken.
2.1 Intended Use
HIMatrix components are designed for assembling safety-related controller systems.
When using the components in the HIMatrix system, comply with the following general
requirements.
2.1.1 Environmental Requirements
Requirement type Range of values 1)
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
1) The values specified in the technical data apply and are decisive for devices with extended
environmental requirements.
Table 3: Environmental Requirements
Exposing the HIMatrix system to environmental conditions other than those specified in this
manual can cause the HIMatrix 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 devices.
NOTE
Device damage due to electrostatic discharge!
When performing the work, make sure that the workspace 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.

2 Safety CIO 2/4 01
Page 10 of 40 HI 800 199 E Rev. 2.00
2.2 Residual Risk
No imminent risk results from a HIMatrix system itself.
Residual risk may result from:
Faults related to engineering
Faults related to the user program
Faults related to the wiring
2.3 Safety Precautions
Observe all local safety requirements and use the protective equipment required on site.
2.4 Emergency Information
A HIMatrix system is a part of the safety equipment of a site. If a device or a module fails, the
system enters the safe state.
In case of emergency, no action that may prevent the HIMatrix systems from operating safely is
permitted.

CIO 2/4 01 3 Product Description
HI 800 199 E Rev. 2.00 Page 11 of 40
3 Product Description
The CIO 2/4 01 is a module for the modular F60 HIMatrix system.
The module can be inserted in the F60 subrack's slot 3...8. Slots 1 and 2 are reserved for the
power supply module and central module, respectively.
The module CIO 2/4 01 has 2 counters and 4 digital outputs, which are galvanically separated
from the I/O bus. The status of the output signals is displayed by LEDs located on the front plate
next to the terminal plugs.
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 and PL e (EN ISO 13849-1) and SIL 4
(EN 50126, EN 50128 and EN 50129).
Further safety standards, application standards and test standards are specified in the
certificates available on the HIMA website.
3.1 Safety Function
If a module fault occurs, the affected outputs are de-energized.
3.1.1 Safety-Related Outputs
The user program controls the 4 safety-related digital outputs of the module.
Connections are provided on the output terminals for the common ground L-.
If an output channel is overloaded, it is switched off for 10 s until the overload is no longer
present. If all 4 outputs of the module have a total load of more than 2 A, they are all switched
off for 10 s.
3.1.1.1 Reaction in the Event of a Fault
If the module detects a faulty signal on a digital output, the affected module output is set to the
safe (de-energized) state using the safety switches.
If a module fault occurs, all digital outputs are switched off.
In both cases, the module activates the ERR LED.
The error code allows the user to configure additional fault reactions in the user program.
3.1.2 Safety-Related Counters
The module is equipped with 2 independent counters with inputs that can be configured for 5 V
or 24 V level.
The required voltage level is determined by the user program with the Counter[0x].5/24V Mode
system parameter.
Input A is the counter input, B is the count direction input and input Z (zero track) is used to
reset. All inputs, including C, are 4-bit Gray code inputs (with decoder operation, see below).
Alternatively, all inputs are 4-bit Gray code inputs (with decoder operation).

3 Product Description CIO 2/4 01
Page 12 of 40 HI 800 199 E Rev. 2.00
The following modes of operation can be implemented:
Counter function 1 (depending on the count direction input signal)
Counter function 2 (irrespective of the count direction input signal)
Decoder operation with attached rotary transducer
Refer to Chapter 3.4.5 for more details on how to configure the counters.
The safety-related counter has a 24-bit resolution, the maximum counter reading is 224 – 1
(= 16 777 215).
3.1.2.1 Reaction in the Event of a Fault
If the module detects a fault in the counter section, a status bit is set for evaluation in the user
program.
In all these cases, the module activates the ERR LED.
In addition to the status bit, the user program must also consider the corresponding error code.
The error code allows the user to configure additional fault reactions in the user program.
3.2 Equipment, Scope of Delivery
The following table specifies the available module variants:
Designation Description
CIO 2/4 01 Module with 2 counter inputs and 4 digital outputs
CIO 2/4 014 Module with 2 counter inputs and 4 digital outputs,
Operating temperature: -25...+70 °C (temperature class T1),
Vibration and shock tested according to EN 50125-3 and EN 50155,
class 1B according to IEC 61373
Table 4: Available Variants

CIO 2/4 01 3 Product Description
HI 800 199 E Rev. 2.00 Page 13 of 40
3.3 Type Label
The type plate contains the following details:
Product name
Bar code (1D or 2D code)
Part no.
Production year
Hardware revision index (HW Rev.)
Firmware revision index (FW Rev.)
Operating voltage
Mark of conformity
Figure 1: Sample Type Label

3 Product Description CIO 2/4 01
Page 14 of 40 HI 800 199 E Rev. 2.00
3.4 Assembly
This chapter describes the layout and function of the module.
3.4.1 Block Diagram
Counter, Channel 1
Counter, Channel 2
I/O Bus
Internal Logic
4 Outputs
Figure 2: Block Diagram

CIO 2/4 01 3 Product Description
HI 800 199 E Rev. 2.00 Page 15 of 40
3.4.2 Front View
CIO 2/4
01
Figure 3: Front View

3 Product Description CIO 2/4 01
Page 16 of 40 HI 800 199 E Rev. 2.00
3.4.3 Module Indicators
LED Color Status Description
On Operating voltage presentRUN Green Off No operating voltage
On Module faulty or external faults
Reaction as dictated by the diagnosis
ERR Red
Off No module faults and / or no channel faults
Table 5: Module Indicators
3.4.4 I/O LEDs
LED Color Status Description
On The related output is active (energized).1...4 Yellow Off The related output is inactive (de-energized).
Table 6: I/O LEDs
3.4.5 Mode of Operation of the Counters
Both counters of the CIO 2/4 01 must be configured using system parameters, see
Chapter 4.3.1 and Chapter 4.4.1.
The following modes of operation can be implemented:
Counter function 1 (depending on the count direction input signal)
Counter function 2 (irrespective of the count direction input signal)
Decoder operation with attached rotary transducer
3.4.5.1 Counter Function 1 (Depending on the Count Direction Input Signal)
Counter[0x].Auto. Detection of Rotation Direction system parameter set to TRUE, counting with
falling edge on input A1 (A2)
Low level on count direction input B1 (B2) increments (increases) the counter value,
High level on count direction input B1 (B2) decrements (decreases) the counter value.
For this mode of operation, the Z1 input (Z2) must be set to low level. The counter can be reset
with a short-time high level.
Input C1 (C2) has no function.
The counter can be reset within the programming tool using the Counter[0x].Reset system
parameter.
Configuration of counter function 1:
System parameter Description Value
Counter[0x].5/24V Mode Inputs 24 V
5V TRUE FALSE
Counter[0x].Auto.
Detection of Rotation
Direction
Counter function 1 active TRUE
Counter[0x].Direction No function FALSE
Counter[0x].Gray Code Pulse operation active FALSE
Counter[0x].Reset Standard
Reset short-time TRUE FALSE
Table 7: Configuration of Counter Function 1

CIO 2/4 01 3 Product Description
HI 800 199 E Rev. 2.00 Page 17 of 40
3.4.5.2 Counter Function 2 (Irrespective of the Count Direction Input Signal)
Counter[0x].Auto. Detection of Rotation Direction system parameter set to FALSE,
counting with falling edge on input A1 (A2).
The counter increment or decrement is not controlled externally via the input B1 (B2), but by the
user program.
Counter[0x].Direction system parameter is set to FALSE: increment (increase) of the counter
value,
Counter[0x].Direction system parameter is set to TRUE: decrement (decrease) of the counter
value
Input B1 (B2) has no function.
The counter can be reset using the Counter[0x].Reset system parameter.
Configuration of counter function 2:
System parameter Description Value
Counter[0x].5/24V Mode Inputs 24 V
5V TRUE FALSE
Counter[0x].Auto.
Detection of Rotation
Direction
Counter function 2 active FALSE
Counter[0x].Direction Incrementing
Decrementing FALSE TRUE
Counter[0x].Gray Code Pulse operation active FALSE
Counter[0x].Reset Standard
Reset short-time TRUE FALSE
Table 8: Configuration of Counter Function 2
3.4.5.3 Decoder Operation with Attached Rotary Transducer
The 4-bit Gray Code of a rotary transducer connected to the inputs A1, B1, Z1, C1 (A2, B2, Z2,
C2) is evaluated.
In the user program, use the Counter[0x].Gray Code system parameter to define this mode of
operation individually.
Configuration of decoder operation:
System parameter Description Value
Counter[0x].5/24V Mode Inputs 24 V
5V TRUE FALSE
Counter[0x].Auto.
Detection of Rotation
Direction
Counter function 1 passive FALSE
Counter[0x].Direction No function FALSE
Counter[0x].Gray Code Decoder operation active TRUE
Counter[0x].Reset Default (no function) TRUE
Table 9: Configuration of Decoder Operation

3 Product Description CIO 2/4 01
Page 18 of 40 HI 800 199 E Rev. 2.00
3.4.5.4 Comparing the Codes Used
When the counter is operated as a decoder in Gray code, only 1 bit may change if a value on
the inputs changes.
4-bit Gray code Decimal value Counter[0x].Value
0000 0 0
0001 1 1
0011 2 3
0010 3 2
0110 4 6
0111 5 7
0101 6 5
0100 7 4
1100 8 12
1101 9 13
1111 10 15
1110 11 14
1010 12 10
1011 13 11
1001 14 9
1000 15 8
Table 10: Comparison of the Codes Used
3.5 Product Data CIO 2/4 01
Counter module
Input voltages 5 V or 24 V
Input current 3 mA
Input resistance 3.7 k
Count frequency 0...1 MHz
Resolution 24-bit
Accuracy of time base 0.2 %
Operating voltage 24 VDC, -15...+20 %, rPP 15 %,
from a power supply unit with safe insulation,
in accordance with IEC 61131-2
Operating data 24 VDC / 0.1 A plus output load
3.3 VDC / 0.8 A
5 VDC / 0.1 A
Ambient temperature 0...+60 °C
Storage temperature -40...+85 °C
Space requirement 6 RU, 4 HP
Weight 260 g
Table 11: Counter Module

CIO 2/4 01 3 Product Description
HI 800 199 E Rev. 2.00 Page 19 of 40
Digital outputs
Number of outputs 4 digital outputs
Output voltage 18.4...26.8 VDC
Output current 0.5 A each channel, max. 2 A each module,
permanently short-circuit-proof
Internal voltage drop max. 3 W at 0.5 A
Minimum load 2 mA for each channel
Leakage current (low level) max. 1 mA at 2 V
Current input 24 VDC / 0.1 A plus output load
Table 12: Digital Outputs
3.5.1 Product Data CIO 2/4 014
The CIO 2/4 014 model variant is intended for use in railway applications. The electronic
components are coated with a protective lacquer.
CIO 2/4 014
Operating temperature -25…+70 °C (temperature class T1)
Table 13: Product Data CIO 2/4 014
The CIO 2/4 014 module meets the vibration and shock requirements in accordance with
EN 61373, Category 1, Class B.

4 Start-up CIO 2/4 01
Page 20 of 40 HI 800 199 E Rev. 2.00
4 Start-up
To start up the module, it must be mounted, connected and configured in the programming tool.
4.1 Installation and Mounting
The module is mounted in the subrack of the modular HIMatrix F60 system.
When laying cables (long cables, in particular), take appropriate measures to avoid interference,
e.g., by separating the signal lines from the power lines.
When dimensioning the cables, ensure that their electrical properties have no negative impact
on the measuring circuit.
4.1.1 Mounting and Removing the Modules
To mount and remove the modules, the connection cable clamp terminals must be unplugged.
Additionally, personnel must be protected from electrostatic discharge. For details, refer to
Chapter 2.1.2.
Mounting the Modules
To mount a module into the subrack
1. Insert the module as far as it can go – without jamming it – into the two guiding rails which
are located on the housing's upper and lower part.
2. Apply pressure to the upper and lower extremity of the front plate until the module plugs
snap into the backplane socket.
3. Secure the module with the screws located on upper and lower extremity of the front plate.
The module is mounted.
Removing the Modules
To remove a module from the subrack
1. Remove the plugs from the module front plate.
2. Release the locking screws located on the upper and lower extremity of the front plate.
3. Loosen the module using the handle located on the lower part of the front plate and remove
it from the guiding rails.
The module is removed.
The inputs and outputs are connected using 9-pole connectors with numbered terminals. The
terminal pins on the front plate of the module have the same numbered sequence to avoid
invalid connections.
4.1.2 Connecting the Counters
Only shielded cables with a maximum length of 500 m must be connected to the counter inputs.
Each measurement input must be connected to a twisted pair of wires. The shielding must be
connected to the controller and the sensor housing and earthed on one end to the controller
side to form a Faraday cage.
All C- terminals are interconnected and have the same voltage.