HIMA HIMatrix DO 8 01 User manual

HIMatrix
Safety-Related Controller
DO 8 01 Manual
HIMA Paul Hildebrandt GmbH + Co KG
Industrial Automation
Rev. 2.00 HI 800 207 E

HI 800 207 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: SIL 4 certified according to EN 50126, EN 50128 and
EN 50129, Chapter 3.4.2 and 4.1.3
Revised: Chapter 3.1 and 3.5
X X

DO 8 01 Table of Contents
HI 800 207 E Rev. 2.00 Page 3 of 34
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
3.2 Equipment, Scope of Delivery 12
3.3 Type Label 12
3.4 Structure 13
3.4.1 Block Diagram 13
3.4.2 Safety-Related Relay Outputs 13
3.4.2.1 Burner Control Applications 14
3.4.2.2 General Safety Applications 14
3.4.3 Front View 15
3.4.4 Status Indicators 16
3.4.5 I/O LEDs 16
3.5 Product Data 17
4Start-up 18
4.1 Installation and Mounting 18
4.1.1 Mounting and Removing the Modules 18
4.1.2 Connecting the Relay Outputs 19
4.1.3 Cable Plugs 19
4.2 Configuration 20
4.2.1 Module Slots 20
4.3 Configuring the Module with SILworX 20
4.3.1 Parameters and Error Codes for the Output 21
4.3.2 Digital Outputs 21
4.3.2.1 Tab Module 21
4.3.2.2 Tab DO 8 01_1: Channels 22

Table of Contents DO 8 01
Page 4 of 34 HI 800 207 E Rev. 2.00
4.4 Configuring the Module with ELOP II Factory 22
4.4.1 Configuring the Outputs 22
4.4.2 Signals and Error Codes for the Output 22
4.4.3 Digital Outputs 23
5Operation 24
5.1 Handling 24
5.2 Diagnosis 24
6Maintenance 25
6.1 Faults 25
6.2 Maintenance Measures 25
6.2.1 Loading the Operating System 25
6.2.2 Proof Test 25
7Decommissioning 26
8Transport 27
9Disposal 28
Appendix 29
Glossary 29
Index of Figures 30
Index of Tables 31
Index 32

DO 8 01 1 Introduction
HI 800 207 E Rev. 2.00 Page 5 of 34
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 DO 8 01
Page 6 of 34 HI 800 207 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.

DO 8 01 1 Introduction
HI 800 207 E Rev. 2.00 Page 7 of 34
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 DO 8 01
Page 8 of 34 HI 800 207 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.

DO 8 01 2 Safety
HI 800 207 E Rev. 2.00 Page 9 of 34
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 II 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 DO 8 01
Page 10 of 34 HI 800 207 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.

DO 8 01 3 Product Description
HI 800 207 E Rev. 2.00 Page 11 of 34
3 Product Description
The DO 8 01 is a module with 8 outputs 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 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 129).
Further safety standards, application standards and test standards are specified in the
certificates available on the HIMA website.
3.1 Safety Function
The safety function meets the integrity requirements described in the corresponding test
standards.
The module is equipped with safety-related relay outputs.
The module is designed in accordance with the de-energize to trip principle. If a system fault
occurs, all relay outputs are set to the de-energized safe state. If a channel fault occurs, only the
affected channel is de-energized.
In both cases, the ERR LED is lit. In addition, reactions in the user program can be triggered
using error codes.
The module can also be used in energized to trip applications. To this end, the relay output is
switched on to perform a safety function (energize to trip).
All instructions on how to use the module specified in the safety manual must be observed.

3 Product Description DO 8 01
Page 12 of 34 HI 800 207 E Rev. 2.00
3.2 Equipment, Scope of Delivery
The following table specifies the available component:
Designation Description
DO 8 01 Module with 8 relay outputs.
Table 4: Available Component
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

DO 8 01 3 Product Description
HI 800 207 E Rev. 2.00 Page 13 of 34
3.4 Structure
This chapter describes the layout and function of the module.
3.4.1 Block Diagram
I/O Bus
Status Indicators
8 Safety-Related Relay Outputs
Figure 2: Block Diagram
3.4.2 Safety-Related Relay Outputs
The module is equipped with eight safety-related relay outputs. Each relay output is switched
via three relays connected in series. One relay is a standard relay, whereas the two other relays
are safety relays with forcibly guided contacts (EN 50205).
All eight relay outputs are electrically safely separated from one another and from the power
supply of the device. For safe separation, the air and creeping distances are designed in
accordance with IEC 61131-2 for overvoltage class II up to 300 V.
The relay outputs are connected with numbered terminals. To facilitate the assignment of the
individual relay outputs, an identical number is located on the front plate of the module, see
Chapter 4.1.2.
The terminal connections and the housing comply with IP20 protection requirements. With
higher requirements, the F60 must be mounted in an enclosure with suitable type of protection.
If voltages other than SELV and PELV are connected, cables with suitable insulation must be
used.
The state of each relay output is signaled by an individual LED, see Chapter 3.4.5.

3 Product Description DO 8 01
Page 14 of 34 HI 800 207 E Rev. 2.00
3.4.2.1 Burner Control Applications
For burner control applications, an internal fuse is used to limit the relay outputs switching
current to 60 % (3.15 A) of the maximum permissible value in accordance with EN 298 and
EN 50156-1 (VDE 0116). The relay outputs can be used for safety shutdowns, i.e., to shutdown
the entire fuel supply.
If burner control applications require a reduced switching current (AC/DC) than the limited
switching current (3.15 A), an external pre-fuse must be switched into the circuit.
The relays in use comply with the contact lifetime required for burner control applications.
mechanical ≥3 x 106switching operations
electrical ≥250 000 switching operations
3.4.2.2 General Safety Applications
The instructions specified in Figure 3 and in Table 9 must be observed for general safety
applications:
The maximum permissible number of switching operations.
The maximum permissible switching currents (up to 3.15 A), voltage and power.
Figure 3: Contact Lifetime AC

DO 8 01 3 Product Description
HI 800 207 E Rev. 2.00 Page 15 of 34
3.4.3 Front View
RUN ERR
1
2
3
4
5
6
7
8
1
21
3
42
5
63
7
84
9
10 5
11
12 6
13
14 7
15
16 8
DO 8
01
Figure 4: Front View

3 Product Description DO 8 01
Page 16 of 34 HI 800 207 E Rev. 2.00
3.4.4 Status 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: Status Indicators
3.4.5 I/O LEDs
LED Color Status Description
On The corresponding channel is active (energized)1...8 Yellow
Off The corresponding channel is not active (de-energized)
Table 6: I/O LEDs

DO 8 01 3 Product Description
HI 800 207 E Rev. 2.00 Page 17 of 34
3.5 Product Data
General
Operating voltage 1) 24 VDC, -15...+20 %, rPP 15 %, at 0…+30 °C 2)
Operating voltage 1)
increased ambient
temperature
24 VDC, ±10 %, rPP 15 %, at >30…+50 °C 3)
24 VDC, -10...-2,5 %, rPP 15 %, at >50...+60 °C 3)
Current input max. 0.7 A
Electrical isolation of the
channels
Yes
Storage temperature -40...+85 °C
Space requirement 6 RU, 4 HP
Weight 300 g
1) From a power supply unit with safe insulation in accordance with IEC 61131-2.
2) Restricted temperature range!
3) With uses at temperatures higher than 30 °C, the operating voltage is only permitted in the
specified range.
Table 7: Product Data
Relay Outputs
Number 8 potential-free normally open contacts
Execution 2 safety relays with forcibly guided contacts,
1 standard relay
Switching voltage 6 V, 250 VAC / 250 VDC
Switching current 10 mA, 3 A,
internally fused with 3.15 A
fuse breaking capacity: 100 A
Type of protection IP40
Contact material Silver alloy, flash plated
Switching time approx. 30 ms
Reset time approx. 20 ms
Bounce time approx. 30 ms
Life time
mechanical
electrical
3 x 106switching operations
see Figure 3
Table 8: Specifications for the Relay Outputs
Relay output switching capacity (general safety applications)
≤30 VDC max. 90 W (3,15 A)
≤70 VDC max. 35 W (0,5 A)
≤127 VDC max. 45 W (0,315 A)
Switching capacity DC
induction-free1)
≤250 VDC max. 60 W (0,25 A)
Switching capacity AC
induction-free 1)
≤250 VAC max. 600 VA
Switching capacity AC
cos φ> 0,5
≤250 VAC max. 400 VA
Switching capacity DC,
UL 508
30 VDC at 3 A, resistive1)
60 VDC at 0,3 A, resistive1)
1) Circuit induction-free
- Free-wheeling diode
- Use suitable protective circuit, i.g., RC elements, Zener diodes or varistors
Table 9: Relays Output Switching Capacity

4 Start-up DO 8 01
Page 18 of 34 HI 800 207 E Rev. 2.00
4 Start-up
To start up the controller, 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.

DO 8 01 4 Start-up
HI 800 207 E Rev. 2.00 Page 19 of 34
4.1.2 Connecting the Relay Outputs
The use of shielded cables is not required, but improves the EMC conditions significantly. To
allow the connection of the clamps to the earth grid of the F60, the diameter of the cable
shielding should not exceed 12 mm.
The output contacts are connected in pairs using connectors with numbered terminals. The
terminal pins on the front plate of the module have the same numbered sequence to avoid
invalid connections.
The terminal connections comply with IP20 protection requirements. With higher requirements,
an enclosure with suitable type of protection must be used for the F60.
If voltages other than SELV and PELV are connected, suitable cables with double or increased
insulation must be used, e.g., power cables.
The relay outputs are connected as follows:
Terminal Designation Function
1 Contact 1, terminal A
2 1 Contact 1, terminal B
3 Contact 2, terminal A
4 2 Contact 2, terminal B
5 Contact 3, terminal A
6 3 Contact 3, terminal B
7 Contact 4, terminal A
8 4 Contact 4, terminal B
9 Contact 5, terminal A
10 5 Contact 5, terminal B
11 Contact 6, terminal A
12 6 Contact 6, terminal B
13 Contact 7, terminal A
14 7 Contact 7, terminal B
15 Contact 8, terminal A
16 8 Contact 8, terminal B
Table 10: Terminal Assignment for the Relay Outputs
4.1.3 Cable Plugs
Cable plugs attached to the pin headers of the module are used to connect to the field zone.
The cable plugs are included within the scope of delivery of the HIMatrix modules.
Connection to the field zone
Number of cable plugs 8 pieces, two poles, screw terminals
Wire cross-section 0.2…2.5 mm2 (single-wire)
0.2…1.5 mm2(finely stranded)
0.2…1.5 mm2(with wire end ferrule)
Stripping length 13 mm
Screwdriver Slotted 0.6 x 3.5 mm
Tightening torque 0.4…0.5 Nm
Table 11: Cable Plug Properties

4 Start-up DO 8 01
Page 20 of 34 HI 800 207 E Rev. 2.00
4.2 Configuration
The module can be configured using a programming tool, SILworX or ELOP II Factory. Which
programming tool should be used, depends on the revision status of the operating system
(firmware):
SILworX is required for CPU OS V7 and higher.
ELOP II Factory is required for CPU OS up to V6.x.
iHow to switch between operating systems is described in Chapter Loading Operating Systems
of the system manual for the modular F60 system (HI 800 191 E).
4.2.1 Module Slots
Slots 1 and 2 on the F60 subrack are reserved for the PS 01 power supply module and the
central module, respectively. Any type of I/O modules can be plugged in to slots 3...8.
The module slots in SILworX and ELOP II Factory are numbered as follows:
Module Slot on the rack Slot in SILworX Slot in ELOP II Factory
PS 01 1 - -
CPU/COM 2 0/1 -
I/O 3 2 1
I/O 4 3 2
I/O 5 4 3
I/O 6 5 4
I/O 7 6 5
I/O 8 7 6
Table 12: Module Slots
i
The PS 01 power supply module is not configured.
CPU and COM are both on the central module. In the programming tools, however, they are
represented as separate items.
4.3 Configuring the Module with SILworX
In the Hardware Editor, the controller is represented with the following modules:
one processor module (CPU)
one communication module (COM)
6 slots available for I/O modules
To insert I/O modules, drag them from the module list onto an available slot.
Double-click the module to open the Detail View with the corresponding tabs. The tabs are used
to assign the global variables configured in the user program to the system parameters of the
corresponding module.