HIMA HIMatrix F60 User manual

HIMatrix
Safety-Related Controller
DI 32 01 Manual
HIMA Paul Hildebrandt GmbH + Co KG
Industrial Automation
Rev. 2.00 HI 800 203 E

HI 800 203 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: DI 32 014, SIL 4 certified according to EN 50126,
EN 50128 and EN 50129, Chapter 4.1.3 X X

DI 32 01 Table of Contents
HI 800 203 E Rev. 2.00 Page 3 of 38
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 Inputs 11
3.1.1.1 Reaction in the Event of a Fault 11
3.1.1.2 Line Control 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 Front View 14
3.4.3 Status Indicators 15
3.4.4 I/O LEDs 15
3.5 Product Data 16
3.5.1 Product Data DI 32 014 16
4Start-up 17
4.1 Installation and Mounting 17
4.1.1 Mounting and Removing the Modules 17
4.1.2 Connecting the Digital Inputs 17
4.1.2.1 Surges on Digital Inputs 19
4.1.3 Cable Plugs 19
4.1.4 Mounting the DI 32 01 in Zone 2 20
4.2 Configuration 21
4.2.1 Module Slots 21
4.3 Configuration with SILworX 22
4.3.1 Parameters and Error Codes for the Inputs 22
4.3.2 Inputs 22
4.3.2.1 Tab Module 23
4.3.2.2 Tab DI 32 01: Channels 24

Table of Contents DI 32 01
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4.4 Configuration with ELOP II Factory 24
4.4.1 Configuring the Inputs 24
4.4.2 Signals and Error Codes for the Inputs 24
4.4.3 Digital Inputs 25
5Operation 27
5.1 Handling 27
5.2 Diagnosis 27
6Maintenance 28
6.1 Faults 28
6.2 Maintenance Measures 28
6.2.1 Loading the Operating System 28
6.2.2 Proof Test 28
7Decommissioning 29
8Transport 30
9Disposal 31
Appendix 33
Glossary 33
Index of Figures 34
Index of Tables 35
Index 36

DI 32 01 1 Introduction
HI 800 203 E Rev. 2.00 Page 5 of 38
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 DI 32 01
Page 6 of 38 HI 800 203 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.

DI 32 01 1 Introduction
HI 800 203 E Rev. 2.00 Page 7 of 38
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 DI 32 01
Page 8 of 38 HI 800 203 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.

DI 32 01 2 Safety
HI 800 203 E Rev. 2.00 Page 9 of 38
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 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 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 DI 32 01
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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.

DI 32 01 3 Product Description
HI 800 203 E Rev. 2.00 Page 11 of 38
3 Product Description
The DI 32 01 is a module with 32 digital inputs and is used for the modular F60 system. The
inputs are galvanically separated to the I/O bus.
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
3.1.1 Safety-Related Inputs
The module is equipped with safety-related inputs.The module is equipped with safety-related
inputs. These inputs are divided in 4 groups of 7 inputs and 1 group of 4 inputs (I29...I32). Refer
to Table 10 for more information about terminal assignment. Each group is equipped with a
common short-circuit-proof supply LS+.
3.1.1.1 Reaction in the Event of a Fault
If the module detects a fault on a digital input, the user program processes a low level in
accordance with the de-energized to trip principle.
The module activates the ERR 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 used to detect short-circuits or open-circuits, e.g., on EMERGENCY STOP inputs
complying with Cat. 4 and PL e in accordance with EN ISO 13849-1. Line control can be
configured for the F60 system.
Application example: The outputs DO 1 and DO 2 of the DIO 24/16 01 module are connected to
the digital inputs (DI) of the same module or of the F60 DI 32 01 module as follows:
DI 3 4
DO 1
2
DI 1
2
EMERGENCY STOP 1
EMERGENCY STOP 2 EMERGENCY STOP switches in
accordance with EN 60947-5-1 and
EN 60947-5-5
Figure 1: Line Control

3 Product Description DI 32 01
Page 12 of 38 HI 800 203 E Rev. 2.00
The digital outputs are pulsed. This allows monitoring of the wires to the digital inputs of the
F60 DI 32 01 or F60 DIO 24/16 01 module.
A fault reaction is triggered if one of the following faults occurs:
Cross-circuit between two parallel wires.
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 reaction includes the following actions:
The ERROR LED on the controller's front plate blinks.
The inputs are set to 0.
An evaluable error code is created.
3.2 Equipment, Scope of Delivery
The following table specifies the available module variants:
Designation Description
DI 32 01 Module with 32 digital inputs
DI 32 014 Module with 32 digital inputs,
Operating temperature: -25...+70 °C (temperature class T1),
Vibration and shock tested according to EN 50125-3 and EN 50155,
class 1B according to IEC 61373
Table 4: Available Variants
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 2: Sample Type Label

DI 32 01 3 Product Description
HI 800 203 E Rev. 2.00 Page 13 of 38
3.4 Structure
This chapter describes the layout and function of the module.
3.4.1 Block Diagram
Test
32 Channels I/O Bus
Figure 3: Block Diagram

3 Product Description DI 32 01
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3.4.2 Front View
DI 32
01
Figure 4: Front View

DI 32 01 3 Product Description
HI 800 203 E Rev. 2.00 Page 15 of 38
3.4.3 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
3.4.4 I/O LEDs
LED Color Status Description
On The related channel is active (energized).I 1...32 Yellow Off The related channel is inactive (de-energized).
Table 6: I/O LEDs

3 Product Description DI 32 01
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3.5 Product Data
General
Operating voltage 24 VDC, -15...+20 %, rPP 15 %,
from a power supply unit with safe insulation,
in accordance with IEC 61131-2
Operating data 3.3 VDC / 0.05 A
24 VDC / 0.2 A
Ambient temperature 0...+60 °C
Storage temperature -40...+85 °C
Space requirement 6 RU, 4 HP
Weight 260 g
Table 7: Product Data
Digital inputs
Number of inputs 32, galvanically separated
Input voltage
High level
Low level
nom. 24 VDC
10...30 V
max. 5 V
Input current
High level
Low level
2 mA at 10 V, 5 mA at 24 V
1 mA at 5 V
Switching point typ. 7.5 V
Supply 5 x 20 V / 100 mA (at 24 V), short-circuit-proof, current limited
Table 8: Specifications for Digital Inputs
3.5.1 Product Data DI 32 014
The DI 32 014 model variant is intended for use in railway applications. The electronic
components are coated with a protective lacquer.
DI 32 014
Operating temperature -25…+70 °C (temperature class T1)
Table 9: Product Data DI 32 014
The DI 32 014 module meets the vibration and shock requirements in accordance with
EN 61373, Category 1, Class B.

DI 32 01 4 Start-up
HI 800 203 E Rev. 2.00 Page 17 of 38
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.
4.1.2 Connecting the Digital Inputs
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 inputs are connected using 9-pole connectors with numbered terminals. The terminal pins
on the front plate of the module have the same numbered sequence to avoid invalid
connections.

4 Start-up DI 32 01
Page 18 of 38 HI 800 203 E Rev. 2.00
Use the following terminals to connect the inputs:
Terminal Designation Function
01 LS+ Supply for inputs 1...7
02 I1 Digital input 1
03 I2 Digital input 2
04 I3 Digital input 3
05 I4 Digital input 4
06 I5 Digital input 5
07 I6 Digital input 6
08 I7 Digital input 7
09 EGND Ground
Terminal Designation Function
10 LS+ Supply for inputs 8...14
11 I8 Digital input 8
12 I9 Digital input 9
13 I10 Digital input 10
14 I11 Digital input 11
15 I12 Digital input 12
16 I13 Digital input 13
17 I14 Digital input 14
18 EGND Ground
Terminal Designation Function
19 LS+ Supply for inputs 15...21
20 I15 Digital input 15
21 I16 Digital input 16
22 I17 Digital input 17
23 I18 Digital input 18
24 I19 Digital input 19
25 I20 Digital input 20
26 I21 Digital input 21
27 EGND Ground
Terminal Designation Function
28 LS+ Supply for inputs 22...28
29 I22 Digital input 22
30 I23 Digital input 23
31 I24 Digital input 24
32 I25 Digital input 25
33 I26 Digital input 26
34 I27 Digital input 27
35 I28 Digital input 28
36 EGND Ground
Terminal Designation Function
37 LS+ Supply for inputs 29...32
38 I29 Digital input 29
39 I30 Digital input 30
40 I31 Digital input 31
41 I32 Digital input 32

DI 32 01 4 Start-up
HI 800 203 E Rev. 2.00 Page 19 of 38
Terminal Designation Function
42 EGND Ground
43 EGND Ground
44 EGND Ground
45 EGND Ground
Table 10: Terminal Assignment for the Inputs
4.1.2.1 Surges on Digital Inputs
Due to the short cycle time of the HIMatrix systems, a surge pulse as described in
EN 61000-4-5 can be read in to the digital inputs as a short-term high level.
The following measures ensure proper operation in environments where surges may occur:
1. Install shielded input wires
2. Program noise blanking in the user program. A signal must be present for at least two cycles
before it is evaluated. The fault reaction is triggered with a corresponding delay.
iThe measures specified above are not necessary if the plant design precludes surges from
occurring within the system.
In particular, the design must include protective measures with respect to overvoltage,
lightning, earth grounding and plant wiring in accordance with the relevant standards and the
instructions specified in the System Manual (HI 800 141 E or HI 800 191 E).
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 5 pieces, nine poles, screw terminals
Wire cross-section 0.2…1.5 mm2 (single-wire)
0.2…1.5 mm2(finely stranded)
0.2…1.5 mm2(with wire end ferrule)
Stripping length 6 mm
Screwdriver Slotted 0.4 x 2.5 mm
Tightening torque 0.2…0.25 Nm
Table 11: Cable Plug Properties

4 Start-up DI 32 01
Page 20 of 38 HI 800 203 E Rev. 2.00
4.1.4 Mounting the DI 32 01 in Zone 2
(EC Directive 94/9/EC, ATEX)
The module is suitable for mounting in zone 2. Refer to the corresponding declaration of
conformity available on the HIMA website.
When mounting the device, observe the special conditions specified in the following section.
Specific Conditions X
1. Mount the HIMatrix F60 controller in an enclosure that meets the EN 60079-15 requirements
and achieves a type of protection of at least IP54, in accordance with EN 60529. Provide the
enclosure with the following label:
Work is only permitted in the de-energized state
Exception:
If a potentially explosive atmosphere has been precluded, work can also performed when the
controller is under voltage.
2. The enclosure in use must be able to safely dissipate the generated heat. The power
dissipation of the DI 32 01 module is 7 W at maximum depending on the power supply
voltage.
3. The 24 VDC power must come from a power supply unit with safe isolation. Use power
supply units of type PELV or SELV only.
4. Applicable standards:
VDE 0170/0171 Part 16, DIN EN 60079-15: 2004-5
VDE 0165 Part 1, DIN EN 60079-14: 1998-08
Pay particular attention to the following sections:
DIN EN 60079-15:
Chapter 5 Design
Chapter 6 Terminals and cabling
Chapter 7 Air and creeping distances
Chapter 14 Connectors
DIN EN 60079-14:
Chapter 5.2.3 Equipment for use in zone 2
Chapter 9.3 Cabling for zones 1 and 2
Chapter 12.2 Equipment for zones 1 and 2
The controller is additionally equipped with the label represented below:
Figure 5: Label for Ex Conditions