HIMA HIMatrix F1 DI 16 01 User manual

HIMatrix
Safety-Related Controller
F1 DI 16 01 Manual
HIMA Paul Hildebrandt GmbH + Co KG
Industrial Automation
Rev. 1.01 HI 800 153 E

HI 800 153 E Rev. 1.01 (1025)
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
1.01 Deleted: Chapter Monitoring the Temperature State displaced into
the system manual
X

F1 DI 16 01 Table of Contents
HI 800 153 E Rev. 1.01 Page 3 of 42
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 Digital Inputs ................................................................................. 11
3.1.1.1 Reaction in the Event of a Fault............................................................................. 12
3.1.2 Line Control............................................................................................................ 12
3.2 Equipment, Scope of Delivery............................................................................ 13
3.2.1 IP Address and System ID (SRS) .......................................................................... 13
3.3 Type Label ............................................................................................................ 14
3.4 Assembly.............................................................................................................. 15
3.4.1 LED Indicators ....................................................................................................... 16
3.4.1.1 Operating Voltage LED .......................................................................................... 16
3.4.1.2 System LEDs ......................................................................................................... 17
3.4.1.3 Communication LEDs ............................................................................................ 18
3.4.1.4 I/O LEDs ................................................................................................................ 18
3.4.2 Communication...................................................................................................... 19
3.4.2.1 Connections for Ethernet Communication ............................................................. 19
3.4.2.2 Network Ports Used for Ethernet Communication ................................................. 19
3.4.3 Pulsed Outputs ...................................................................................................... 20
3.4.4 Reset Key .............................................................................................................. 20
3.5 Product Data......................................................................................................... 21
3.5.1 Product Data F1 DI 16 011 (-20 °C)....................................................................... 21
3.6 Certified HIMatrix F1 DI 16 01 ............................................................................. 22

Table of Contents F1 DI 16 01
Page 4 of 42 HI 800 153 E Rev. 1.01
4Start-Up................................................................. 23
4.1 Installation and Mounting....................................................................................23
4.1.1 Connection of the Digital Inputs..............................................................................23
4.1.1.1 Surges on Digital Inputs .........................................................................................24
4.1.2 Connection of Digital Pulsed Outputs.....................................................................24
4.1.3 Mounting the F1 DI 16 01 in Zone 2.......................................................................25
4.2 Configuration........................................................................................................26
4.3 Configuration with SILworX ................................................................................26
4.3.1 Parameters and Error Codes for the Inputs and Output......................................... 26
4.3.2 Digital Inputs F1 DI 16 01.......................................................................................26
4.3.2.1 Module Tab............................................................................................................27
4.3.2.2 DI 16: DO-Channels Tab.......................................................................................28
4.3.2.3 DI 16: DI-Channels Tab ........................................................................................28
4.4 Configuring a Remote I/O Using ELOP II Factory .............................................29
4.4.1 Configuring the Inputs and Outputs........................................................................29
4.4.2 Signals and Error Codes for the Inputs and Output................................................29
4.4.3 Digital Inputs F1 DI 16 01.......................................................................................30
4.4.4 Pulsed Outputs F1 DI 16 01 ...................................................................................31
5Operation .............................................................. 32
5.1 Handling................................................................................................................32
5.2 Diagnosis ..............................................................................................................32
6Maintenance.......................................................... 33
6.1 Faults.....................................................................................................................33
6.1.1 Operating System Version 6.42 and Beyond .........................................................33
6.1.2 Operating System Versions Prior to 6.42 ...............................................................33
6.2 Maintenance Measures........................................................................................33
6.2.1 Loading the Operating System...............................................................................33
6.2.2 Proof Test...............................................................................................................33
7Decommissioning.................................................. 34
8Transport .............................................................. 35
9Disposal................................................................ 36
Appendix............................................................... 37
Glossary................................................................................................................37
Index of Figures....................................................................................................38
Index of Tables .....................................................................................................39
Index......................................................................................................................40

F1 DI 16 01 1 Introduction
HI 800 153 E Rev. 1.01 Page 5 of 42
1 Introduction
This manual describes the technical characteristics of the device 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
SILworX Versions Beyond 7
ELOP II Factory Versions Prior to 7
Table 1: HIMatrix System Variants
The manual distinguishes among the different variants using:
Separated chapters,
Tables differentiating among the versions, e.g., versions beyond 7, or prior to 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 F1 DI 16 01
Page 6 of 42 HI 800 153 E Rev. 1.01
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.

F1 DI 16 01 1 Introduction
HI 800 153 E Rev. 1.01 Page 7 of 42
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 F1 DI 16 01
Page 8 of 42 HI 800 153 E Rev. 1.01
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.

F1 DI 16 01 2 Safety
HI 800 153 E Rev. 1.01 Page 9 of 42
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 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 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 F1 DI 16 01
Page 10 of 42 HI 800 153 E Rev. 1.01
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.

F1 DI 16 01 3 Product Description
HI 800 153 E Rev. 1.01 Page 11 of 42
3 Product Description
The safety-related F1 DI 16 01 remote I/O is a compact system in a metal enclosure with
16 digital inputs and 4 pulsed outputs.
The remote I/O is available in two model variants for SILworX and two model variants for
ELOP II Factory. All variants are described in this manual.
The remote I/O serves to extend the I/O level of HIMax and HIMatrix controllers, and is
connected to them via safeethernet. The remote I/O itself is not able to run a user program.
The HIMatrix remote I/Os are not multi-master capable.
The remote I/O is suitable for mounting in Ex-zone 2, see Chapter 4.1.3.
The device 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
The remote I/O is equipped with safety-related inputs. The input values on the inputs are
safely transmitted to the connected controller via safeethernet.
3.1.1 Safety-Related Digital Inputs
The remote I/O is equipped with 16 digital inputs. The state (HIGH, LOW) of each input is
signaled by an individual LED.
Mechanical contacts without own power supply or signal power source can be connected to
the inputs. Potential-free mechanical contacts without own power supply are fed via an
internal short-circuit-proof 24 V power source (LS+). Each 24 V power source supplies a
group of 4 mechanical contacts. Figure 1 shows how the connection is performed.
With signal voltage sources, the corresponding ground must be connected to the input (L-),
see Figure 1.
DI 1
LS+
DI 4 DI 3 DI 2
DI 1
L-
DI 4 DI 3 DI 2
Connection of potential-free
mechanical contacts
Connection of signal power sources
Figure 1: Connections to Safety-Related Digital Inputs
For the external wiring and the connection of sensors, apply the de-energized-to-trip
principle. Thus, if a fault occurs, the input signals adopt a de-energized, safe state (low
level).
An external wire is not monitored, however, an open-circuit is considered as safe low level.

3 Product Description F1 DI 16 01
Page 12 of 42 HI 800 153 E Rev. 1.01
3.1.1.1 Reaction in the Event of a Fault
If the device detects a fault on a digital input, the user program processes a low level in
accordance with the de-energized to trip principle.
The device activates the FAULT LED.
In addition to the channel signal value, 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.
3.1.2 Line Control
Line control is a monitoring function for detecting short-circuits or open-circuits and can be
configured for the remote I/O, e.g., on EMERGENCY STOP inputs complying with Cat. 4 in
accordance with EN 954-1.
To this end, connect the pulsed outputs TO 1...TO 2 of the system to the digital inputs (DI)
of the same system as follows:
EMERGENCY STOP 1
EMERGENCY STOP 2
EMERGENCY STOP devices in
accordance with EN 60947-5-1 and
EN 60947-5-5
Figure 2: Line Control
The remote I/O pulses the pulsed outputs (TO) to detect the line short-circuits and open-
circuits to the digital inputs (DI). To do so, configure the Value [BOOL] -> system variable in
SILworX and the DO[0x].Value system signal in ELOP II Factory. The variables for the
pulsed outputs must begin with channel 1 and reside in direct sequence, one after the
other.
If the following faults occur, the FAULT LED located on the front plate of the controller
blinks, the inputs are set to low level and an (evaluable) error code is created:
Cross-circuit between two parallel lines,
Improper connections of two lines (e.g., TO 2 to DI 3),
Earth fault of a line (with earthed ground only),
Open-circuit or open contacts, i.e., including when one of the two EMERGENCY STOP
switches mentioned above has been engaged, the FAULT LED blinks and the error
code is created.

F1 DI 16 01 3 Product Description
HI 800 153 E Rev. 1.01 Page 13 of 42
For more information on how to configure line control in the user program, refer to the
HIMatrix Engineering Manual HI 800 101 E.
3.2 Equipment, Scope of Delivery
The available variants and their part numbers are listed below:
Designation Description Part no.
F1 DI 16 01 Remote I/O with 16 digital inputs, operating
temperature 0...+60 °C, for ELOP II Factory
programming tool.
98 2200405
F1 DI 16 011
(-20 °C)
Remote I/O with 16 digital inputs, operating
temperature -20...+60 °C, for ELOP II Factory
programming tool.
98 2200456
F1 DI 16 01
SILworX
Remote I/O with 16 digital inputs, operating
temperature 0...+60 °C, for SILworX programming
tool.
98 2200479
F1 DI 16 011
SILworX
(-20 °C)
Remote I/O with 16 digital inputs, operating
temperature -20...+60 °C, for SILworX
programming tool.
98 2200488
Table 4: Part Numbers
3.2.1 IP Address and System ID (SRS)
A transparent label is delivered with the device to allow one to note the IP address and the
system ID (SRS for system rack slot) after a change.
IP___.___.___.___SRS____.__.__
Default value for IP address: 192.168.0.99
Default value for SRS: 60000.200.0 (SILworX)
60000.0.0 (ELOP II Factory)
The label must not be affixed such that the air vents on the enclosure are covered.
Refer to the First Steps manual of the programming tool for more information on how to
modify the IP address and the system ID.

3 Product Description F1 DI 16 01
Page 14 of 42 HI 800 153 E Rev. 1.01
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 3: Sample Type Label

F1 DI 16 01 3 Product Description
HI 800 153 E Rev. 1.01 Page 15 of 42
3.4 Assembly
This chapter describes the layout and function of the remote I/Os, and their communication
via safeethernet.
DI
16 01
1
Figure 4: Front View
16 Digital Inputs
Safety-Related Processor System
Switch
Watchdog
4 Pulsed Outputs
Figure 5: Block Diagram

3 Product Description F1 DI 16 01
Page 16 of 42 HI 800 153 E Rev. 1.01
3.4.1 LED Indicators
The light-emitting diodes (LEDs) indicate the operating state of the remote I/O. The LEDs
are classified as follows:
Operating voltage LED
System LEDs
Communication LEDs
I/O LEDs
3.4.1.1 Operating Voltage LED
LED Color Status Description
On 24 VDC operating voltage present24 VDC Green
Off No operating voltage
Table 5: Operating Voltage LED

F1 DI 16 01 3 Product Description
HI 800 153 E Rev. 1.01 Page 17 of 42
3.4.1.2 System LEDs
While the system is being booted, all LEDs are lit simultaneously.
LED Color Status Description
On Device in RUN, normal operation
A loaded user program is being executed (not with remote I/Os).
Blinking Device in STOP
A new operating system is being loaded.
RUN Green
Off The device is not in the RUN state.
On The device is in the ERROR STOP state.
Internal fault detected by self-tests
e.g., hardware fault, software error or cycle time overrun.
The processor system can only be restarted with a command from
the PADT (reboot).
Blinking If ERROR blinks and all others LEDs are lit simultaneously, the boot
loader has detected an operating system fault in the flash memory
and waits for a new operating system to be loaded.
ERROR Red
Off No faults detected.
On A new configuration is being loaded into the device.
Blinking The device switches from INIT to STOP
A new operating system is being loaded into the flash ROM.
PROG Yellow
Off No configuration or operating system is being loaded.
On The device is in RUN, forcing was activated.
Blinking The device is in STOP, forcing has been prepared and is activated
when the device is started.
FORCE Yellow
Off Forcing is not activated.
The FORCE LED of a remote I/O is not functioning. The FORCE
LED of the associated controller serves to signal the forcing of a
remote I/O.
On The loaded configuration is defective.
The new operating system is corrupted (after OS download).
Blinking Fault while loading a new operating system
One or multiple I/O faults occurred.
FAULT Yellow
Off None of the described faults occurred.
Blinking Operating system emergency loader active.OSL Yellow
Off Operating system emergency loader inactive.
Blinking OS and OLS binary defective or INIT_FAIL hardware fault.BL Yellow
Off Boot loader inactive
Table 6: System LEDs

3 Product Description F1 DI 16 01
Page 18 of 42 HI 800 153 E Rev. 1.01
3.4.1.3 Communication LEDs
All RJ-45 connectors are provided with a green and a yellow LED. The LEDs signal the
following states:
LED Status Description
On Full duplex operation
Blinking Collision
Green
Off Half duplex operation, no collision
On Connection available
Blinking Interface activity
Yellow
Off No connection available
Table 7: Ethernet Indicators
3.4.1.4 I/O LEDs
LED Color Status Description
On The related channel is active (energized).DI 1...16 Yellow
Off The related channel is inactive (de-energized).
On Pulsed output activated.TO 1...4 Yellow
Off Pulsed output deactivated.
Table 8: I/O LEDs

F1 DI 16 01 3 Product Description
HI 800 153 E Rev. 1.01 Page 19 of 42
3.4.2 Communication
The remote I/O communicates with the associated controller via safeethernet.
3.4.2.1 Connections for Ethernet Communication
Property Description
Port 2 x RJ-45
Transfer standard 10/100/Base-T, half and full duplex
Auto negotiation Yes
Auto crossover Yes
Connection socket RJ-45
IP address Freely configurable1)
Subnet mask Freely configurable1)
Supported protocols Safety-related: safeethernet
Non-safety-related:
programming and debugging tool (PADT), SNTP
1) The general rules for assigning IP address and subnet masks must be adhered to.
Table 9: Ethernet Interfaces Properties
The two RJ-45 connectors with integrated LEDs are located on the bottom left-hand side of
the enclosure. For more information on the communication LEDs, refer to Chapter 3.4.1.3.
The connection parameters are read based on the MAC address (media access control
address) defined during manufacturing.
The MAC address for the remote I/O is specified on a label located above the two RJ-45
connectors (1 and 2).
Figure 6: Sample MAC Address Label
The remote I/O is equipped with an integrated switch for safety-related Ethernet
communication (safeethernet). For further information on the integrated switch and
safeethernet, refer to Chapter Communication of the System Manual for Compact Systems
HI 800 141 E.
3.4.2.2 Network Ports Used for Ethernet Communication
UDP ports Usage
8000 Programming and operation with the programming tools
8001 Configuration of the remote I/O using the PES (ELOP II Factory)
8004 Configuration of the remote I/O using the PES (SILworX)
6010 safeethernet
123 SNTP (time synchronization between PES and remote I/O, PES and
external devices)
Table 10: Network Ports in Use

3 Product Description F1 DI 16 01
Page 20 of 42 HI 800 153 E Rev. 1.01
3.4.3 Pulsed Outputs
The 4 digital pulsed outputs can be used for Line Control to detect short-circuits and open-
circuits on digital inputs, e.g., on an EMERGENCY STOP button complying with Cat. 4 in
accordance with EN 954-1.
iPulsed outputs must not be used as safety-related outputs (e.g., for activating safety-
related actuators)!
3.4.4 Reset Key
The remote I/O is equipped with a reset key. The key is only required if the user name or
password for administrator access is not known. If only the IP address set for the remote
I/O does not match the PADT (PC), the connection can be established with a Route add
entry on the PC.
The key can be accessed through a small round hole located approximately 5 cm from the
upper left-hand side of the enclosure. The key is engaged using a suitable pin made of
insulating material to avoid short-circuits within the remote I/O.
The reset is only effective if the remote I/O is rebooted (switched off and on) while the key
is simultaneously engaged for at least 20 seconds. Engaging the key during operation has
no effect.
Properties and behavior of the remote I/IO after a reboot with engaged reset key:
Connection parameters (IP address and system ID) are set to the default values.
All accounts are deactivated except for the administrator default account with empty
password.
After a new reboot without the reset key engaged, the connection parameters (IP address
and system ID) and accounts become effective.
Those configured by the user.
Those valid prior to rebooting with the reset key engaged, if no changes were
performed.