HIMA HIMatrix M45 User manual

HIMatrix M45
Safety-Related Controller
Manual M-DI 8 01
HIMA Paul Hildebrandt GmbH + Co KG
Industrial Automation
Rev. 1.00 HI 800 661 E

HI 800 661 E Rev. 1.00 (1343)
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: [e-mail]
Revision
index
Revisions
Type of change
technical
editorial
1.00
First edition of the HIMatrix M45 manual

M-DI 8 01 Table of Contents
HI 800 661 E Rev. 1.00 Page 3 of 46
Table of Contents
1Introduction 5
1.1 Structure and Use of this Manual 5
1.2 Target Audience 5
1.3 Formatting Conventions 6
1.3.1 Safety Notes 6
1.3.2 Operating Tips 7
2Safety 8
2.1 Intended Use 8
2.1.1 Environmental Requirements 8
2.1.2 ESD Protective Measures 8
2.2 Residual Risk 9
2.3 Safety Precautions 9
2.4 Emergency Information 9
3Product Description 10
3.1 Safety Function 10
3.1.1 Reaction in the Event of a Fault 10
3.2 Scope of Delivery 10
3.3 Type Label 11
3.4 Structure 12
3.4.1 Safety-Related Digital Inputs 12
3.4.1.1 Standard Mode of Operation 12
3.4.1.2 Line Control Mode of Operation 12
3.4.1.3 Test Pulse Blanking Mode of Operation 12
3.4.2 Digital Outputs 13
3.4.2.1 Supply Mode of Operation 13
3.4.2.2 Pulsed Output Mode of Operation 13
3.4.2.3 DO Non-Safety-Related Mode of Operation 13
3.4.3 Block diagram 14
3.4.4 Front View 15
3.4.5 LED Indicators 16
3.4.5.1 Module Status Indicators 16
3.4.5.2 I/O Indicators 17
3.5 Product Data 18
3.6 Socket 19
3.6.1 Mechanical Coding 19
3.6.2 Coding M-DI 8 01 Module and Socket 20
3.6.2.1 Configuring the Socket Coding 20
3.6.3 Socket M-SO I/O 01 21
3.6.3.1 Terminal Assignment for the Field Terminals 22
3.6.3.2 Field Terminal Properties 22
4Start-Up 23
4.1 Mounting 23
4.1.1 Surges on Digital Inputs 23
4.1.2 Wiring Inputs Not in Use 23

Table of Contents M-DI 8 01
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4.2 Mounting and Removing the Modules and the Socket 24
4.2.1 Mounting a Socket 24
4.2.2 Mounting and Removing the Module 26
4.3 Line Control 27
4.3.1 Connecting Pulsed Outputs 27
4.3.2 Configuring Line Control 28
4.4 Configuration with SILworX 29
4.4.1 Tab Module 30
4.4.2 Tab M-DI 8 01_1: Channels 31
4.5 Connection Variants 32
4.5.1 Connection of Electromechanical Control Circuit Devices 32
4.5.2 Redundant Wiring 33
4.5.3 Connecting 3-Wire Proximity Switches 34
5Operation 35
5.1 Handling 35
5.2 Diagnosis 35
6Maintenance 36
6.1 Faults 36
6.2 Maintenance Measures 36
6.2.1 Loading the Operating System 36
6.2.2 Proof Test 36
7Decommissioning 37
8Transport 38
9Disposal 39
Appendix 41
Glossary 41
Index of Figures 42
Index of Tables 43
Index 44

M-DI 8 01 1 Introduction
HI 800 661 E Rev. 1.00 Page 5 of 46
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 in SILworX.
1.1 Structure and Use of this Manual
The content of this manual is part of the hardware description of the HIMatrix M45
programmable electronic system.
This manual is organized in the following main chapters:
Introduction
Safety
Product Description
Start-Up
Operation
Maintenance
Decommissioning
Transport
Disposal
Additionally, the following documents must be taken into account:
Name
Content
Document no.
HIMatrix M45
Safety Manual
Safety functions of the HIMatrix
system
HI 800 653 E
HIMatrix M45
System Manual
Hardware description of the
HIMatrix M45
HI 800 651 E
SILworX
Communication Manual
Description of communication and
protocols
HI 801 101 E
SILworX Online Help (OLH)
Instructions on how to use SILworX
-
First Steps Manual
Introduction to SILworX
HI 801 103 E
Table 1: 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.

1 Introduction M-DI 8 01
Page 6 of 46 HI 800 661 E Rev. 1.00
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 if 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
SIGNAL WORD
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

M-DI 8 01 1 Introduction
HI 800 661 E Rev. 1.00 Page 7 of 46
1.3.2 Operating Tips
Additional information is structured as presented in the following example:
i
The text corresponding to the additional information is located here.
Useful tips and tricks appear as follows:
TIP
The tip text is located here.

2 Safety M-DI 8 01
Page 8 of 46 HI 800 661 E Rev. 1.00
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.
The 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
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 2: 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.

M-DI 8 01 2 Safety
HI 800 661 E Rev. 1.00 Page 9 of 46
2.2 Residual Risk
No imminent risk results from a HIMatrix M45 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 M45 system is a part of the safety equipment of a plant. If a device or a module fails,
the system enters the safe state.
In case of emergency, no action that may prevent the HIMatrix M45 systems from operating
safely is permitted.

3 Product Description M-DI 8 01
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3 Product Description
The M-DI 8 01 digital input module is intended for use in the HIMatrix M45 system.
Up to 64 I/O modules can be used in a HIMatrix M45 system, if the structure conditions are met
in accordance with the safety manual (HI 800 651 E).
The module is equipped with the following inputs and outputs:
Inputs/outputs
Numb
er
Function
Safety-Related Digital
Inputs
8
Depending on the selected mode of operation
- Standard (DI)
- Line Control
- Test Pulse Blanking
Digital Outputs
(non-safety-related)
2
Depending on the selected mode of operation
- Supply
- Pulsed output
- DO Non-Safety-Related
Table 3: Module Inputs and Outputs
The module has been certified by the TÜV for safety-related applications up to SIL 3
(IEC 61508, IEC 61511, IEC 62061 and EN 50156) as well as PL e (EN ISO 13849-1).
Further safety standards, application standards and test standards are specified in the
certificates available on the HIMA website.
3.1 Safety Function
The module evaluates the digital input signals and provides them to the user program.
The safety function is performed in accordance with SIL 3.
3.1.1 Reaction in the Event of a Fault
If the safety-related processor system of the module detects a module fault or a channel fault
during operation, the module adopts the safe state. All the outputs are in accordance with the
de-energize-to-trip principle and low level is processed by the inputs.
In both cases, the Err LED is flashing.
3.2 Scope of Delivery
The module must be installed on a suitable socket to be able to operate. The socket is not
included within the scope of delivery of the module.
The socket is described in Chapter 3.6.

M-DI 8 01 3 Product Description
HI 800 661 E Rev. 1.00 Page 11 of 46
3.3 Type Label
The type plate contains the following details:
Product name
Mark of conformity
Bar code (2D code)
Part number (Part-No.)
Hardware revision index (HW Rev.)
Operating system revision index (OS-Rev.)
Operating data (Power:)
Production year (Prod-Year:)
Figure 1: Sample Type Label

3 Product Description M-DI 8 01
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3.4 Structure
The chapter contains the following sections:
Safety-Related Digital Inputs
Digital Outputs
Block Diagram
LED Indicators
The module is equipped with a safety-related 1oo2D processor system and performs the
following functions:
Evaluation of the digital inputs and outputs
Control and monitoring of the I/O level
The process data and states of the module are provided to the processor module (M-CPU) via
the system bus.
3.4.1 Safety-Related Digital Inputs
The module is equipped with 8 digital inputs that are not galvanically separated from one
another.
The digital inputs can be configured for the following options:
Standard (safety-related digital input)
Line Control
Test Pulse Blanking
3.4.1.1 Standard Mode of Operation
The Standard mode of operation evaluates digital input signals of electromechanical control
circuit devices (mechanical contact) and proximity switches (2 or 3-wire device).
3.4.1.2 Line Control Mode of Operation
The Line Control mode of operation evaluates digital input signals of electromechanical control
circuit devices (mechanical contact) and proximity switches (2 or 3-wire device).
Additionally, the inputs were checked for open-circuit and short-circuit, see Chapter 4.3.
3.4.1.3 Test Pulse Blanking Mode of Operation
A low level must be present for at least two module cycles to be detected as low signal. This
ensures that test pulses are pulsed out, e.g., from light grids.

M-DI 8 01 3 Product Description
HI 800 661 E Rev. 1.00 Page 13 of 46
3.4.2 Digital Outputs
The module is equipped with 2 non-safety-related outputs. Each output is attached on two
clamps (1 and 7, 4 and 10). The outputs are current limited. The state (HIGH, LOW) of each
output is signaled by an individual LED (HIGH, LOW).
The outputs can be configured for the following options:
Supply
Pulsed Output
DO Non-Safety-Related
The setting is configured via the Mode of Output X system parameter. Each of the two outputs
can be configured individually.
3.4.2.1 Supply Mode of Operation
In this mode of operation, a voltage is present permanently at the output terminals, which can
be used to supply control circuit devices and proximity switches. The Supply mode of operation
is the default setting.
3.4.2.2 Pulsed Output Mode of Operation
In this mode of operation, the module pulses the outputs to detect open-circuits and short
circuits. Refer to Chapter 4.3 for configuring the mode of operation for the use of line control.
The pulse signal can not be configured.
3.4.2.3 DO Non-Safety-Related Mode of Operation
In this mode of operation, the outputs can be switched via application program. To do this,
global variables must be assigned to the parameters Output 1 and Output 2. The two outputs
can be used as non-safety-related digital outputs.

3 Product Description M-DI 8 01
Page 14 of 46 HI 800 661 E Rev. 1.00
3.4.3 Block diagram
The following block diagram illustrates the structure of the module.
12345678910 11 12
DI 1 2 3 4 5 6 7 8
L+ L-
Stop
Run
Init
Err
M-SO I/O 01 M-DI 8 01
TO1 2
3
4
2
1
5
6
System Bus
Switch
Watchdog
Safety-Related Processor System
Interface
Field Zone: Proximity Switch and
Mechanical Contact
Figure 2: Block Diagram

M-DI 8 01 3 Product Description
HI 800 661 E Rev. 1.00 Page 15 of 46
3.4.4 Front View
The following figure shows the front view of the module.
Figure 3: Front View

3 Product Description M-DI 8 01
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3.4.5 LED Indicators
The LEDs indicate the operating state of the module. The LEDs are classified as follows:
Module status indicators
I/O indicators
When the supply voltage is switched on, a LED test is performed and all LEDs are briefly lit.
Definition of Blinking Frequencies
The following table defines the blinking frequencies of the LEDs:
Name
Blinking frequencies
Blinking1
Long (approx. 600 ms) on, long (approx. 600 ms) off
Blinking2
Short (approx. 200 ms) on, short (approx. 200 ms) off, short (approx. 200 ms)
on, long (approx. 600 ms) off
Blinking-x
Ethernet communication: Blinking synchronously with data transfer
Table 4: Blinking Frequencies of LEDs
3.4.5.1 Module Status Indicators
The LEDs signal the following states:
LED
Color
Status
Description
Run
Green
On
Module in RUN, normal operation
Blinking1
Module state:
STOP/OS_DOWNLOAD or
OPERATE (only with processor modules)
OFF
Module not in RUN,
observe the other status LEDs.
Err
Red
On
Missing license for additional functions
(e.g. communication protocols), test mode.
Blinking1
System error, e. g.:
Internal module fault detected by self-tests,
e.g., hardware or voltage supply.
Fault while loading the operating system.
Blinking2
Field fault, but no internal fault
OFF
Normal operation
Stop
Yellow
On
Module state:
STOP / VALID CONFIGURATION
Blinking1
Module state:
STOP / INVALID CONFIGURATION or
STOP / LOADING OS
OFF
Module not in STOP,
observe the other status LEDs.
Init
Yellow
On
Module state: INIT
Blinking1
Module state:
LOCKED or
STOP / LOADING OS
OFF
Module state: neither INIT nor LOCKED,
observe the other status LEDs.
Table 5: Module Status Indicators

M-DI 8 01 3 Product Description
HI 800 661 E Rev. 1.00 Page 17 of 46
3.4.5.2 I/O Indicators
The LEDs of the I/O indicators are labeled DI and TO.
LED
Color
Status
Description
DI 1…8
Yellow
On
The related input is active (energized).
Blinking2
The related channel is faulty.
OFF
The related input is inactive (de-energized).
TO 1…2
Yellow
On
The related output is active (energized).
Blinking2
The related channel is faulty.
OFF
The related output is inactive (de-energized).
Table 6: I/O LEDs

3 Product Description M-DI 8 01
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3.5 Product Data
General
Supply voltage
24 VDC, -15...+20 %, rp≤ 5 %,
PELV, SELV
Max. supply voltage
30 VDC
Current input
80 mA at 24 VDC
Max. 90 mA
Max. reaction time of the module1)
6.2 ms
Ambient temperature
0…+60 °C
Storage temperature
-40…+85 °C
Humidity
Max. 95 % relative humidity, non-condensing
Type of protection
IP20
Dimensions without socket
(H x W x D) in mm
105 x 12.5 x 72
Dimensions with socket up to DIN rail
(H x W x D) in mm
105 x 12.7 x 90
Weight
Module
Socket
approx. 65 g
approx. 55 g
1) In case of an internal fault
Table 7: Product Data
Digital inputs
Number of inputs (number of
channels)
8, non-galvanically separated, common ground L-
Type of input
Current sinking logic, 24 V, type 1 and type 3 in
accordance with IEC 61131-2
Rated input voltage
24 VDC
Low level
-3…+5 VDC
High level
+15…+30 VDC at min. 2 mA
Switching point
Typ. 10 VDC
Table 8: Specifications for Digital Inputs
Digital outputs
Number of outputs (number of
channels)
2, non-galvanically separated, common ground L-
Output voltage
L+ minus 2 V
Output current
Max. 200 mA
Leakage current per channel (with low
level)
Max. 1 mA at 2 V
Switching time
On: ≤30 µs
Off: ≤ 80 µs
Table 9: Specifications for the Outputs

M-DI 8 01 3 Product Description
HI 800 661 E Rev. 1.00 Page 19 of 46
3.6 Socket
Socket and module form together a functional unit. The module is connected to the system bus,
the power supply and the field zone via socket. The field lines are connected to the socket's
tension clamp terminals, see Figure 5.
3.6.1 Mechanical Coding
Modules and sockets are mechanically coded, see Figure 4. The coding of the modules is set
ex works by the position of the coding pins. Two coding sockets accept the coding pins and
must be set to the selected module, see Chapter 3.6.2. Coding avoids installation of improper
I/O modules.
Upper Coding Pin
Lower Coding Pin
Upper Coding Socket
Lower Coding Socket
Figure 4: Sample Coding of Module and Socket

3 Product Description M-DI 8 01
Page 20 of 46 HI 800 661 E Rev. 1.00
3.6.2 Coding M-DI 8 01 Module and Socket
To attach the module, the coding of the M-SO I/O 01 socket must be set as follows:
Order
Module coding (rear
view)
Position
Coding socket
Top
2
Below
3
Table 10: Module and Socket Coding
3.6.2.1 Configuring the Socket Coding
Tools and utilities:
Screwdriver, slotted 0.8 x 4.0 mm
Configuring the upper and lower coding socket
1. Insert the screwdriver into the opening of the upper coding socket.
2. Turn the screwdriver until the required coding is set.
3. Repeat these steps for the lower coding socket.
4. Sample the module onto the socket
5. Remove Module