HIMA HIMatrix F20 User manual

HIMatrix
Safety-Related Controller
F20 Manual
HIMA Paul Hildebrandt GmbH + Co KG
Industrial Automation
Rev. 1.01 HI 800 143 E

HI 800 143 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

F20 Table of Contents
HI 800 143 E Rev. 1.01 Page 3 of 56
Table of Contents
1Introduction ............................................................ 7
1.1 Structure and Use of this Manual......................................................................... 7
1.2 Target Audience..................................................................................................... 8
1.3 Formatting Conventions ....................................................................................... 9
1.3.1 Safety Notes ............................................................................................................ 9
1.3.2 Operating Tips ....................................................................................................... 10
2Safety.................................................................... 11
2.1 Intended Use ........................................................................................................ 11
2.1.1 Environmental Requirements................................................................................. 11
2.1.2 ESD Protective Measures...................................................................................... 11
2.2 Residual Risk ....................................................................................................... 12
2.3 Safety Precautions............................................................................................... 12
2.4 Emergency Information....................................................................................... 12
3Product Description .............................................. 13
3.1 Safety Function.................................................................................................... 13
3.1.1 Safety-Related Digital Inputs ................................................................................. 13
3.1.1.1 Reaction in the Event of a Fault............................................................................. 14
3.1.1.2 Line Control............................................................................................................ 14
3.1.2 Safety-Related Digital Outputs............................................................................... 15
3.1.2.1 Reaction in the Event of a Fault............................................................................. 16
3.2 Equipment, Scope of Delivery............................................................................ 17
3.2.1 IP Address and System ID (SRS) .......................................................................... 17
3.3 Type Label ............................................................................................................ 18
3.4 Assembly.............................................................................................................. 19
3.4.1 LED Indicators ....................................................................................................... 20
3.4.1.1 Operating Voltage LED .......................................................................................... 20
3.4.1.2 System LEDs ......................................................................................................... 21
3.4.1.3 Communication LEDs ............................................................................................ 22
3.4.1.4 I/O LEDs ................................................................................................................ 22
3.4.1.5 Fieldbus LEDs........................................................................................................ 22
3.4.2 Communication...................................................................................................... 23
3.4.2.1 Connections for Ethernet Communication ............................................................. 23
3.4.2.2 Network Ports Used for Ethernet Communication ................................................. 23
3.4.2.3 Connections for Fieldbus Communication ............................................................. 24
3.4.3 Pin Assignments .................................................................................................... 24
3.4.3.1 Pin Assignment of the D-sub Connector FB1 ........................................................ 24
3.4.3.2 Pin Assignment of the D-sub Connector FB1 ........................................................ 25
3.4.3.3 Pin Assignment of the D-sub Connector FB1 ........................................................ 25
3.4.3.4 Pin Assignment of the D-sub Connector FB1 ........................................................ 25
3.4.3.5 Pin Assignment of the D-sub Connector FB1 ........................................................ 26
3.4.3.6 Pin Assignment of the D-sub Connector FB2 ........................................................ 26
3.4.4 Reset Key .............................................................................................................. 27

Table of Contents F20
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3.4.5 Fan .........................................................................................................................27
3.4.5.1 Replacing the Fan ..................................................................................................28
3.4.5.2 Replacement Interval .............................................................................................28
3.4.6 Hardware Clock......................................................................................................28
3.5 Product Data.........................................................................................................29
3.6 Certified HIMatrix F20 ..........................................................................................31
4Start-Up................................................................. 32
4.1 Installation and Mounting....................................................................................32
4.1.1 Connection of the Digital Inputs..............................................................................32
4.1.1.1 Surges on Digital Inputs .........................................................................................32
4.1.2 Connecting the Digital Outputs............................................................................... 33
4.1.3 Connecting Pulsed Outputs.................................................................................... 33
4.1.4 Mounting the F20 in Zone 2 ...................................................................................34
4.2 Configuration........................................................................................................35
4.3 Configuration with SILworX ................................................................................35
4.3.1 Parameters and Error Codes for the Inputs and Output......................................... 35
4.3.2 Digital Inputs and Outputs for F20..........................................................................36
4.3.2.1 Module Tab............................................................................................................36
4.3.2.2 DIO 8/8: DO Channels Tab ...................................................................................37
4.3.2.3 DIO 8/8: DI Channels Tab..................................................................................... 38
4.3.3 Pulsed Outputs for F20 ..........................................................................................39
4.3.3.1 Module Tab............................................................................................................39
4.3.3.2 DO 4: Channels Tab .............................................................................................39
4.4 Configuring a Controller Using ELOP II Factory...............................................40
4.4.1 Configuring the Inputs and Outputs........................................................................40
4.4.2 Signals and Error Codes for the Inputs and Output................................................40
4.4.3 Digital Inputs for F20 ..............................................................................................41
4.4.4 Digital Outputs for F20 ...........................................................................................43
4.4.5 Pulsed Outputs for F20 ..........................................................................................44
5Operation .............................................................. 45
5.1 Handling................................................................................................................45
5.2 Diagnosis ..............................................................................................................45
6Maintenance.......................................................... 46
6.1 Faults.....................................................................................................................46
6.1.1 Operating System Version 6.42 and Beyond .........................................................46
6.1.2 Operating System Versions Prior to 6.42 ...............................................................46
6.2 Maintenance Measures........................................................................................46
6.2.1 Loading the Operating System...............................................................................46
6.2.2 Proof Test...............................................................................................................46
7Decommissioning.................................................. 47
8Transport .............................................................. 48
9Disposal................................................................ 49

F20 Table of Contents
HI 800 143 E Rev. 1.01 Page 5 of 56
Appendix............................................................... 51
Glossary................................................................................................................ 51
Index of Figures................................................................................................... 52
Index of Tables..................................................................................................... 53
Index...................................................................................................................... 54

Table of Contents F20
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F20 1 Introduction
HI 800 143 E Rev. 1.01 Page 7 of 56
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 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 F20
Page 8 of 56 HI 800 143 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
HIMax Communication
Manual
Description of the communication
protocols, ComUserTask and their
configuration in SILworX
HI 801 101 E
HIMatrix PROFIBUS DP
Master/Slave Manual
Description of the PROFIBUS
protocol and its configuration in ELOP
II Factory
HI 800 009 E
HIMatrix Modbus
Master/Slave Manual
Description of the Modbus protocol
and its configuration in ELOP II
Factory
HI 800 003 E
HIMatrix
TCP S/R Manual
Description of the TCP S/R protocol
and its configuration in ELOP II
Factory
HI 800 117 E
HIMatrix ComUserTask
(CUT) Manual
Description of the ComUserTask and
its configuration in ELOP II Factory
HI 800 329 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.

F20 1 Introduction
HI 800 143 E Rev. 1.01 Page 9 of 56
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 F20
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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.

F20 2 Safety
HI 800 143 E Rev. 1.01 Page 11 of 56
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 F20
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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.

F20 3 Product Description
HI 800 143 E Rev. 1.01 Page 13 of 56
3 Product Description
The safety-related F20 controller is a compact system in a metal enclosure with 8 digital
input and output (DIO) channels that can be configured as digital inputs or digital outputs.
Additionally, 4 pulsed outputs are available. For external communication, 2 Ethernet
connection and 2 fieldbus interfaces.
A fan located in the enclosure cover contantly cools down the device.
The controller is available in a model variant for SILworX and a model variant for ELOP II
Factory, see Chapter 3.2. All variants are described in this manual.
The device is suitable for mounting in Ex-zone 2, see Chapter 4.1.4.
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 controller is equipped with 8 safety-related, digital channels (DIO), which can be
individually configured as digital input or digital output. The state (HIGH, LOW) of each
input is signaled by an individual LED.
3.1.1 Safety-Related Digital Inputs
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 of them supply 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).
If an external wire is not monitored, an open-circuit is considered as safe low level.

3 Product Description F20
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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.
3.1.1.2 Line Control
Line control is a monitoring function for detecting short-circuits or open-circuits and can be
configured for the F20 system, 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 4 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 controller pulses the pulsed outputs to detect the line short-circuits and line breaks to
the digital inputs. To do so, configure the Value [BOOL] -> system variable in SILworX or
the DO[01].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.
In the programming tool, use an assigned variable to set the DI Pulse Delay system
variable to at least 500 µs.
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.

F20 3 Product Description
HI 800 143 E Rev. 1.01 Page 15 of 56
For more information on how to configure line control in the user program, refer to the
HIMatrix Engineering Manual (HI 800 101 E).
3.1.2 Safety-Related Digital Outputs
The controller is equipped with 8 channels, which can be individually configured as digital
input or digital output.
To configure a digital channel as an output in SILworX, use the Channel [BOOL] -> system
parameter, to configure it in ELOP II Factory, use the DO[xx].Used system signal.
The digital channel can only be used as an output, if the value of the corresponding system
variable is set to TRUE. The variable of the respective input displays the current output
state.
At the maximum ambient temperature, the outputs 1...3 and 5...7 can be loaded with 0.5 A
each; and outputs 4 and 8 can be loaded with 1 A or with 2 A at an ambient temperature of
up to 50 °C.
If an overload occurs, one or all outputs are switched off. If the overload is removed, the
outputs are switched on again automatically, see Table 21.
A short-circuit detected on the output is signaled. The external output line, however, is not
monitored.
DO1
L-
DO1 DO1 DO1
L-
Figure 3: Connection of Actuators to Outputs
The redundant connection of two outputs must be decoupled with diodes.
WARNING
For connecting a load to a 1-pole switching output, use the corresponding L- ground
of the respective channel group (2-pole connection) to ensure that the internal
protective circuit can function.
Inductive loads may be connected with no free-wheeling diode on the actuator. However,
HIMA strongly recommends connecting a protective diode directly to the actuator.

3 Product Description F20
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3.1.2.1 Reaction in the Event of a Fault
If the device 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 device occurs, all digital outputs are switched off.
In both cases, the devices activates the FAULT LED.
The error code allows the user to configure additional fault reactions in the user program.

F20 3 Product Description
HI 800 143 E Rev. 1.01 Page 17 of 56
3.2 Equipment, Scope of Delivery
The following list specifies the available components and the corresponding part numbers:
Designation Description Part no.
F20 01 Compact controller with 8 digital channels that
can be configured as inputs or outputs and 4
pulsed outputs.
Operating temperature 0…+60 °C, for ELOP II
Factory programming tool
98 2200417
F20 01
SILworX
Compact controller with 8 digital channels that
can be configured as inputs or outputs and 4
pulsed outputs.
Operating temperature 0…+60 °C, for SILworX
programming tool
98 2200474
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: 60000.0.0
The label must not be affixed such that the air vents on the cabinet 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 F20
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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 4: Sample Type Label

F20 3 Product Description
HI 800 143 E Rev. 1.01 Page 19 of 56
3.4 Assembly
This chapter describes the layout and function of the controller, and their connection for
communication.
Figure 5: Front View
Digital Channels
Safety-Related Processor System
Dual Port RAM
Communication System
Switch
Watchdog
Pulsed Outputs
Figure 6: Block Diagram

3 Product Description F20
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3.4.1 LED Indicators
The light-emitting diode (LEDs) indicate the operating state of the controller. The LEDs are
classified as follows:
Operating Voltage LED
System LEDs
Communication LEDs
I/O LEDs
Fieldbus 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