HIMA HIMatrix F60 CPU 01 User manual

HIMatrix
Safety-Related Controller
CPU 01 Manual
HIMA Paul Hildebrandt GmbH + Co KG
Industrial Automation
Rev. 1.01 HI 800 189 E

HI 800 189 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

CPU 01 Table of Contents
HI 800 189 E Rev. 1.01 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
3.2 Equipment, Scope of Delivery............................................................................ 11
3.2.1 IP Address and System ID (SRS) .......................................................................... 11
3.3 Type Label ............................................................................................................ 12
3.4 Assembly.............................................................................................................. 13
3.4.1 Block Diagram........................................................................................................ 13
3.4.2 Front View.............................................................................................................. 14
3.4.3 LED Indicators ....................................................................................................... 15
3.4.3.1 System Light Emitting Diodes ................................................................................ 15
3.4.3.2 Program Light Emitting Diodes .............................................................................. 16
3.4.3.3 Communication Indicators ..................................................................................... 17
3.4.4 Operating System .................................................................................................. 17
3.4.5 User Program......................................................................................................... 17
3.4.6 Communication...................................................................................................... 18
3.4.6.1 Connections for Ethernet Communication ............................................................. 18
3.4.6.2 Network Ports Used for Ethernet Communication ................................................. 18
3.4.6.3 Connections for Fieldbus Communication ............................................................. 19
3.4.7 Pin Assignments .................................................................................................... 19
3.4.7.1 Pin Assignment of D-sub Connectors FB1 and FB2.............................................. 19
3.4.7.2 Pin Assignment of D-sub Connectors FB1 and FB2.............................................. 19
3.4.7.3 Pin Assignment of D-sub Connectors FB1 and FB2.............................................. 20
3.4.7.4 Pin Assignment of D-sub Connectors FB1 and FB2.............................................. 20
3.4.7.5 Pin Assignment of D-sub Connectors FB1 and FB2.............................................. 20
3.4.8 Reset Key .............................................................................................................. 21
3.4.9 Monitoring the Operating Voltage .......................................................................... 21
3.5 Product Data......................................................................................................... 22
3.6 Certified HIMatrix F60 CPU 01 ............................................................................ 23

Table of Contents CPU 01
Page 4 of 40 HI 800 189 E Rev. 1.01
4Start-Up................................................................. 24
4.1 Installation and Mounting....................................................................................24
4.1.1 Mounting and Removing the Modules.................................................................... 24
4.1.2 Mounting the CPU 01 in Zone 2 .............................................................................25
4.2 Configuration........................................................................................................26
4.2.1 Module Slots...........................................................................................................26
4.3 Configuring the Module with SILworX................................................................26
4.4 Configuring a Module Using ELOP II Factory....................................................27
5Operation .............................................................. 28
5.1 Handling................................................................................................................28
5.2 Diagnosis ..............................................................................................................28
6Maintenance.......................................................... 29
6.1 Faults.....................................................................................................................29
6.1.1 Operating System Version 6.42 and Beyond .........................................................29
6.1.2 Operating System Versions Prior to 6.42 ...............................................................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

CPU 01 1 Introduction
HI 800 189 E Rev. 1.01 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 Versions beyond 7 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., 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 CPU 01
Page 6 of 40 HI 800 189 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.

CPU 01 1 Introduction
HI 800 189 E Rev. 1.01 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 CPU 01
Page 8 of 40 HI 800 189 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.

CPU 01 2 Safety
HI 800 189 E Rev. 1.01 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
Housing 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 CPU 01
Page 10 of 40 HI 800 189 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.

CPU 01 3 Product Description
HI 800 189 E Rev. 1.01 Page 11 of 40
3 Product Description
The CPU 01 module is the central component of the HIMatrix F60 controller.
The module can only be inserted in the slot located on the right, next to the power supply
module of the HIMatrix F60 subrack. It is used to store the operating system and the user
program, and executes all central functions, including communication with the PADT and
other systems. It monitors the operating voltage and operating temperature.
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.
Module's faults are signaled by the ERR LED located on the front plate, see Chapter 3.4.3.
3.1 Safety Function
The CPU monitors the sequence and the proper, logical execution of the operating system
and user program. The following functions are time monitored:
CPU hardware and software self-tests
CPU RUN cycle (including the user program)
I/O tests and processing of I/O signals
For further information on the fault reaction of the processor module, refer to Chapter 6.1.
3.2 Equipment, Scope of Delivery
The following list specifies the available components and the corresponding part numbers:
Designation Description Part no.
CPU 01 Central module, for ELOP II Factory programming tool 98 2200126
CPU 01 SILworX Central module, for SILworX programming tool 98 2200137
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 be affixed such that the ventilation slots in the housing are not obstructed.
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 CPU 01
Page 12 of 40 HI 800 189 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 1: Sample Type Label

CPU 01 3 Product Description
HI 800 189 E Rev. 1.01 Page 13 of 40
3.4 Assembly
This chapter describes the layout and function of the plug-in module, and its communication
via safeethernet.
3.4.1 Block Diagram
Communication System
Dual Port RAM
I/O Bus Module
Program Memory
Data Memory in NVRAM.
Watchdog
safety related processor system
Figure 2: Block Diagram

3 Product Description CPU 01
Page 14 of 40 HI 800 189 E Rev. 1.01
3.4.2 Front View
CPU 01
RUN
RUN
PROG
BL
FORCE
ERR
STOP
FAULT
OSL
FB1
FB2
2
10/100BaseT
3
4
1
Figure 3: Front View of CPU 01

CPU 01 3 Product Description
HI 800 189 E Rev. 1.01 Page 15 of 40
3.4.3 LED Indicators
The light-emitting diodes (LEDs) indicate the operating state of the device. The LEDs are
classified as follows:
System LEDs
Program LEDs
Communication LEDs
Fieldbus LEDs
3.4.3.1 System Light Emitting Diodes
While the system is being booted, all LEDs are lit simultaneously.
LED Color Status Description
On Module in STOP or RUN, normal operation
Blinkin
g
A new operating system is being loaded.
RUN Green
Off The controller is not in the RUN state.
On The controller 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).
Blinkin
g
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.
ERR Red
Off No faults detected.
Table 5: System Light Emitting Diodes

3 Product Description CPU 01
Page 16 of 40 HI 800 189 E Rev. 1.01
3.4.3.2 Program Light Emitting Diodes
While the system is being booted, all LEDs are lit simultaneously.
LED Color Status Description
On The controller is in the RUN state. The user program is in
the RUN or FREEZE state.
RUN Green
Off The controller is not in the RUN state.
On The controller is in STOP.STOP Red
Off The controller is in RUN or a new operating system is being
loaded.
On The controller is being loaded with a new configuration.
Blinkin
g
The controller 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 loaded configuration is defective.
The new operating system is corrupted (after OS download).
Blinkin
g
Fault while loading a new operating system
One or multiple faults occurred.
FAULT Yellow
Off None of the described faults occurred.
On The controller is in RUN, and forcing was activated.
Blinkin
g
The PES is in STOP, but forcing has been prepared and is
activated when the PES is started.
FORCE Yellow
Off Forcing is not activated.
Blinkin
g
Operating system emergency loader active.
OSL Yellow
Off Operating system emergency loader inactive.
Blinkin
g
OS and OLS binary defective or INIT_FAIL hardware fault.
BL Yellow
Off Boot loader inactive
Table 6: Indicator Program Light Emitting Diodes

CPU 01 3 Product Description
HI 800 189 E Rev. 1.01 Page 17 of 40
3.4.3.3 Communication Indicators
Safe communication via safeethernet is signaled by 2 small LEDs integrated in all RJ-45
connectors:
LED Color Status Description
On Full duplex operation
Blinking Collision
COL Green
Off Half duplex operation, no collision
On Connection availableTx Yellow
Blinking Interface activity
Table 7: Indicators for safeethernet Communication
Additionally, D-sub connectors and 2 corresponding LEDs are available for indicating non
safe communication via fieldbuses:
LED Color Status Description
On RS485, fieldbus 1 is activeFB1 Yellow
Blinking FB1 and FB2 blink simultaneously: Emergency loader is
active
On RS485, fieldbus 2 is activeFB2 Yellow
Blinking FB2 and FB1 blink simultaneously: Emergency loader is
active
Table 8: Indicators for Fieldbus Communication
3.4.4 Operating System
The operating system loaded into the CPU contains all basic functions of the HIMatrix
programmable electronic system (PES), e.g.:
Reading the inputs and writing to the outputs
Processing the user program
Performing all test routines for hardware and software
Cycle time monitoring (watchdog)
Communication with other systems
For a description of the operating system functions and the variables used to configure the
systems and all modules, refer to the HIMatrix System Manual for the Modular F60 System.
3.4.5 User Program
The user program is created using one programming tool, SILworX or ELOP II Factory. It is
then translated into a machine code using the code generator and transferred to the flash
EPROM of CPU module.

3 Product Description CPU 01
Page 18 of 40 HI 800 189 E Rev. 1.01
3.4.6 Communication
The Ethernet interfaces and fieldbus interfaces of the CPU 01 module are used to
communicate with external systems. Each individual Ethernet interface can simultaneously
process several protocols.
iWhen configuring safety-related communication, observe the instructions specified in the
Communication Manual (for SILworX) or the Safety Manual (ELOP II Factory).
3.4.6.1 Connections for Ethernet Communication
Property Description
Ports 4
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
Standard protocols: OPC, programming and debugging
tool (PADT), TCP SR, SNTP, Modbus TCP.
Ethernet/IP (with operating system versions prior to 7 only)
1) The general rules valid for assigning IP address and subnet masks must be adhered to.
Table 9: Connections for Ethernet Communication
The 4 RJ-45 connectors with integrated LEDs are located on the front plate of the module.
Refer to Chapter 3.4.3.3 for a description of the LEDs' function.
The connection parameters are read based on the MAC address (media access control
address) defined during manufacturing.
The MAC address of the module is specified on the label on the rear side of the printed
circuit board. The first MAC address applies for the COM module on the CPU module, the
second for the switch.
Examples of label: MAC-ADR1: 00.E0.A1.00.0E.04 (COM)
MAC ADR2: 00.E0.A1.00.0E.05 (switch)
3.4.6.2 Network Ports Used for Ethernet Communication
UDP ports Use
8000 Programming and operation with the programing tool
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 and OPC
123 SNTP (time synchronization between PES and remote I/O, PES and
external devices)
6005/ 6012 If TCS_DIRECT was not selected in the HH network
502 Modbus (can be modified by the user)
44818 EtherNet/IP session protocol for device identification
2222 EtherNet/IP Data Exchange
Table 10: Network Ports (UDP Ports) in Use

CPU 01 3 Product Description
HI 800 189 E Rev. 1.01 Page 19 of 40
TCP ports Use
502 Modbus (can be modified by the user)
xxx TCP SR assigned by the user
44818 Ethernet/IP Explicit Messaging Services
Table 11: Network Ports (TCP Ports) in Use
3.4.6.3 Connections for Fieldbus Communication
The 2 9-pole D-sub connectors can be accessed through the front plate of the module.
Designation Hardware/ Fieldbus
submodule
Protocols
FB 1
(with module)
PROFIBUS master
PROFIBUS slave
RS485 module
RS232 module
RS422 module
INTERBUS master
PROFIBUS DP master
PROFIBUS DP slave
RS485 for Modbus (master or slave) and
ComUserTask
RS232 for ComUserTask
RS422 for ComUserTask
INTERBUS master
FB 2
(with module)
PROFIBUS master
PROFIBUS slave
RS485 module
RS232 module
RS422 module
INTERBUS master
PROFIBUS DP master
PROFIBUS DP slave
RS485 for Modbus (master or slave) and
ComUserTask
RS232 for ComUserTask
RS422 for ComUserTask
INTERBUS master
Table 12: Connections for Fieldbus Communication
The fieldbus submodules for communication via FB1 and FB2 are optional and must be
mounted by the manufacturer.
3.4.7 Pin Assignments
The following tables describe the Pin assignments of the fieldbus connectors.
3.4.7.1 Pin Assignment of D-sub Connectors FB1 and FB2
with fieldbus submodule for PROFIBUS DP master or slave
Connection Signal Function
1 - - - - - -
2 - - - - - -
3 RxD/TxD-A Receive/send data A
4 RTS Control signal
5 DGND Data reference potential
6 VP 5 V, plus pole supply voltage
7 - - - - - -
8 RxD/TxD-B Receive/send data B
9 - - - - - -
Table 13: Pin Assignment of D-sub Connectors FB1 and FB2 for PROFIBUS DP
3.4.7.2 Pin Assignment of D-sub Connectors FB1 and FB2
with RS485 fieldbus submodule for Modbus master or slave and ComUserTask

3 Product Description CPU 01
Page 20 of 40 HI 800 189 E Rev. 1.01
Connection Signal Function
1 - - - - - -
2 RP 5 V decoupled with diodes
3 RxD/TxD-A Receive/send data A
4 CNTR-A Control signal A
5 DGND Data reference potential
6 VP 5 V, plus pole supply voltage
7 - - - - - -
8 RxD/TxD-B Receive/send data B
9 CNTR-B Control signal B
Table 14: Pin Assignment of the D-sub Connectors FB1 and FB2 for RS485
3.4.7.3 Pin Assignment of D-sub Connectors FB1 and FB2
with RS232 fieldbus submodule for ComUserTask
Connection Signal Function
1 - - - - - -
2 TxD Send data
3 RxD Receive data
4 - - - - - -
5 DGND Data reference potential
6 - - - - - -
7 RTS Request to send
8 - - - - - -
9 - - - - - -
Table 15: Pin Assignment of the D-sub Connectors FB1 and FB2 for RS232
3.4.7.4 Pin Assignment of D-sub Connectors FB1 and FB2
with RS422 fieldbus submodule for ComUserTask
Connection Signal Function
1 - - - - - -
2 RP +5 V decoupled with diodes
3 RxA Receive data A
4 TxA Send data A
5 DGND Data reference potential
6 VP +5 V supply voltage
7 - - - - - -
8 RxB Receive data B
9 TxB Send data B
Table 16: Pin Assignment of the D-sub Connectors FB1 and FB2 for RS422
3.4.7.5 Pin Assignment of D-sub Connectors FB1 and FB2
with fieldbus submodule for INTERBUS