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. 1.00 HI 800 199 E

HI 800 199 E Rev. 1.00 (1014)
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 2010, 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
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Type of Change
Revision
index
Revisions
technical editorial
1.00 Added: Configuration with SILworX X X

CIO 2/4 01 Table of Contents
HI 800 199 E Rev. 1.00 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 ............................................................................................................ 12
3.4 Assembly.............................................................................................................. 13
3.4.1 Block Diagram........................................................................................................ 13
3.4.2 Front View.............................................................................................................. 14
3.4.3 Module Indicators................................................................................................... 15
3.4.4 I/O LEDs ................................................................................................................ 15
3.4.5 Mode of Operation of the Counters........................................................................ 15
3.4.5.1 Counter Function 1 (Depending on the Count Direction Input Signal)................... 15
3.4.5.2 Counter Function 2 (Irrespective of the Count Direction Input Signal)................... 16
3.4.5.3 Decoder Operation with Attached Rotary Transducer ........................................... 16
3.4.5.4 Comparing the Codes Used................................................................................... 17
3.5 Product Data CIO 2/4 01 ...................................................................................... 17
4Start-Up................................................................. 19
4.1 Installation and Mounting ................................................................................... 19
4.1.1 Mounting and Removing the Modules ................................................................... 19
4.1.2 Connecting the Counters ....................................................................................... 19
4.1.3 Connecting the Digital Outputs .............................................................................. 20
4.1.4 Mounting the CIO 2/4 01 in Zone 2........................................................................ 21
4.2 Configuration ....................................................................................................... 22
4.2.1 Module Slots .......................................................................................................... 22

Table of Contents CIO 2/4 01
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4.3 Configuring a Controller with SILworX ..............................................................22
4.3.1 Parameters and Error Codes for the Inputs and Outputs....................................... 23
4.3.2 Counter and Outputs CIO 2/4 01............................................................................ 23
4.3.2.1 Module Tab............................................................................................................23
4.3.2.2 CIO 2/4 01_1: Channels Tab ................................................................................25
4.4 Configuring a Module Using ELOP II Factory....................................................25
4.4.1 Configuring the Inputs and Outputs........................................................................25
4.4.2 Signals and Error Codes for the Inputs and Outputs.............................................. 25
4.4.3 Counter CIO 2/4 01 ................................................................................................ 25
4.4.4 Digital Outputs for CIO 2/4 01 ................................................................................ 27
5Operation .............................................................. 28
5.1 Handling................................................................................................................28
5.2 Diagnosis ..............................................................................................................28
6Maintenance.......................................................... 29
6.1 Faults.....................................................................................................................29
6.2 Maintenance Measures........................................................................................30
6.2.1 Loading the Operating System...............................................................................30
6.2.2 Proof Test...............................................................................................................30
7Decommissioning.................................................. 31
8Transport .............................................................. 32
9Disposal................................................................ 33
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. 1.00 Page 5 of 40
1 Introduction
This manual describes the technical characteristics of the module and its use. It also
includes instructions on how to install, start up and replace it.
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
This manual distinguishes between the following variants of the HIMatrix system:
Programming tool Processor operating system Communication operating
system
SILworX Version 7 and beyond Version 12 and beyond
ELOP II Factory Versions prior to 7 Versions prior to 12
Table 1: HIMatrix System Variants
The manual distinguishes among the different variants using:
Separated chapters
Tables differentiating among the versions, e.g., version 7 and beyond, or prior to
version 7
iProjects created with ELOP II Factory cannot be edited with SILworX, and vice versa!
iThis manual usually refers to compact controllers and remote I/Os as devices, and to the
plug-in cards of a modular controller as modules.

1 Introduction CIO 2/4 01
Page 6 of 40 HI 800 199 E Rev. 1.00
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 Engineering
Manual
Project planning description for
HIMatrix systems
HI 800 101 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,
INTERBUS protocol
-
First Steps
SILworX
Introduction to SILworX using the
HIMax system as an example
HI 801 103 E
First Steps
ELOP II Factory
Introduction to ELOP II Factory HI 800 006 E
Table 2: Additional Relevant Documents
The latest manuals can be downloaded from the HIMA website 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. 1.00 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: 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.
NOTE
Type and source of damage!
Damage prevention
SIGNAL WORD
Type and source of danger!
Consequences arising from the danger
Danger prevention

1 Introduction CIO 2/4 01
Page 8 of 40 HI 800 199 E Rev. 1.00
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. 1.00 Page 9 of 40
2 Safety
The following safety information, notes and instructions 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 danger 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
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
Enclosure Standard: IP20
Supply voltage 24 VDC
Table 3: Environmental Requirements
Exposing the HIMax 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. 1.00
2.2 Residual Risk
No imminent danger results from a HIMatrix system 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 HIMatrix system is a part of the safety equipment of a site. If a device or a module fails,
the site adopts 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. 1.00 Page 11 of 40
3 Product Description
CIO 2/4 01 is a plug-in module for the modular F60 HIMatrix system.
The module can be inserted in the F60 subrack's slot 3...8 as many times as required. Slots
1 and 2 are reserved for the power supply module and CPU module, respectively.
The module CIO 2/4 01 has 2 counters and 4 digital outputs, which are electrically isolated
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 (EN 954-1) and PL e (EN ISO 13849-1). Further
safety standards, application standards and test standards are specified in the certificate
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 seconds until the overload is
removed. If all 4 module outputs are loaded with more than 2 A, they are all switched off for
10 seconds.
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 fault in the module occurs, all digital outputs are switched off.
In both cases, the module activates the FAULT LED.
The error code allows the user to configure additional fault reactions in the user program.
3.1.2 Safety-Related Counters
The device is equipped with 2 independent counters with inputs that can be configured for
5 V or 24 V voltage 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.
Alternatively, all inputs are 4-bit Gray code inputs (with decoder operation)
The following operating modes 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 absolute 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 Product Description CIO 2/4 01
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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 list specifies the available components and the corresponding part numbers:
Designation Description Part no.
CIO 2/4 01 Plug-in module, analog outputs, SIL 3/Cat. 4 98 2200099
Table 4: Part Numbers
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

CIO 2/4 01 3 Product Description
HI 800 199 E Rev. 1.00 Page 13 of 40
3.4 Assembly
This chapter describes the layout and function of the plug-in module.
3.4.1 Block Diagram
Counter, Channel 1
Counter, Channel 2
I/O Bus
Internal Logic
4 Outputs
Figure 2: Block Diagram

3 Product Description CIO 2/4 01
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3.4.2 Front View
CIO 2/4
01
Figure 3: Front View

CIO 2/4 01 3 Product Description
HI 800 199 E Rev. 1.00 Page 15 of 40
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 absolute rotary transducer
3.4.5.1 Counter Function 1 (Depending on the Count Direction Input Signal)
Counter[0x].Auto. Advance Sense 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 (Z2) input 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 2 4 V
5 V
TRUE
FALSE
Counter[0x].Auto.
Advance Sense
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

3 Product Description CIO 2/4 01
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3.4.5.2 Counter Function 2 (Irrespective of the Count Direction Input Signal)
Counter[0x].Auto. Advance Sense 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 within the programming tool using the Counter[0x].Reset system
parameter.
Configuration of counter function 2:
System parameter Description Value
Counter[0x].5/24V Mode Inputs 24 V
5 V
TRUE
FALSE
Counter[0x].Auto.
Advance Sense
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
5 V
TRUE
FALSE
Counter[0x].Auto.
Advance Sense
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

CIO 2/4 01 3 Product Description
HI 800 199 E Rev. 1.00 Page 17 of 40
3.4.5.4 Comparing the Codes Used
When the counter is operated as a decoder in Gray code, only 1 bit may change when 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 kΩ
Count frequency 0...1 MHz
Resolution 24-bit
Accuracy of time base 0.2 %
Operating voltage 24 VDC, -15 %...+20 %, wss ≤15 %,
provided by a power supply unit with safe isolation
in accordance with IEC 61131-2 requirements.
Operating data 24 VDC / 0.1 A incl. output load
3.3 VDC / 0.8 A
5 VDC / 0.1 A
Ambient temperature 0 °C...+60 °C
Storage temperature -40 °C...+85 °C
Space requirement 6 RU, 4 HP
Weight 260 g
Table 11: Counter Module

3 Product Description CIO 2/4 01
Page 18 of 40 HI 800 199 E Rev. 1.00
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 V 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 incl. output load
Table 12: Digital Outputs

CIO 2/4 01 4 Start-Up
HI 800 199 E Rev. 1.00 Page 19 of 40
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.
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 rack
1. Insert the module as far as it can go – without jamming it – into the two guiding rails
which are located on the upper and lower part of the enclosure.
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 rack
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 improper 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
shieldings 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.
NOTE
Using the wrong terminal plugs may damage the module, the sensors or encoders
connected to it!

4 Start-Up CIO 2/4 01
Page 20 of 40 HI 800 199 E Rev. 1.00
The counters are connected to the following terminals:
Terminal Designation Function
01 C- Common ground
02 A1 Input A1 orbit 1
03 B1 Input B1 or bit 2
04 Z1 Input Z1 or bit 3
05 C1 Input C1 or bit 4
06 C- Common ground
07 C- Common ground
08 C- Common ground
09 C- Common ground
Terminal Designation Function
10 C- Common ground
11 A2 Input A2 or bit 1
12 B2 Input B2 or bit 2
13 Z2 Input Z2 or bit 3
14 C2 Input C2 or bit 4
15 C- Common ground
16 C- Common ground
17 C- Common ground
18 C- Common ground
Table 13: Terminal Assignment for the Counters
Inputs that are not being used need not be terminated.
4.1.3 Connecting the Digital Outputs
The use of shielded cables for the outputs is not mandatory, but improves the EMC
conditions significantly. To allow the connection of the clamps to the the earth grid of the
F60, the diameter of the shielded cables should not exceed 12 mm.
Use the following terminals to connect the digital outputs:
Terminal Designation Function
19 L- Common ground
20 1 Digital output 1
21 2 Digital output 2
22 3 Digital output 3
23 4 Digital output 4
24 L- Common ground
25 L- Common ground
26 L- Common ground
27 L- Common ground
Table 14: Terminal Assignment for the Digital Outputs