HIMA HIMatrix User manual

HIMatrix
Safety-Related Controller
AI 8 01 Manual
HIMA Paul Hildebrandt GmbH + Co KG
Industrial Automation
Rev. 1.00 HI 800 195 E

HI 800 195 E Rev. 1.00 (1014)
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
Revision
technical editorial
1.00 Added: Configuration with SILworX X X

AI 8 01 Table of Contents
HI 800 195 E Rev. 1.00 Page 3 of 36
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 Analog Inputs ................................................................................ 11
3.1.1.1 Reaction in the Event of a Fault............................................................................. 12
3.2 Equipment, Scope of Delivery............................................................................ 12
3.3 Type Label ............................................................................................................ 12
3.4 Assembly.............................................................................................................. 13
3.4.1 Block Diagram........................................................................................................ 13
3.4.2 Front View.............................................................................................................. 14
3.4.3 Status Indicators .................................................................................................... 15
3.5 Product Data......................................................................................................... 15
4Start-Up................................................................. 16
4.1 Installation and Mounting ................................................................................... 16
4.1.1 Mounting and Removing the Modules ................................................................... 16
4.1.2 Connection of the Analog Inputs............................................................................ 17
4.1.3 Mounting the AI 8 01 in Zone 2.............................................................................. 18
4.2 Configuration ....................................................................................................... 19
4.2.1 Module Slots .......................................................................................................... 19
4.3 Configuring a Module with SILworX .................................................................. 20
4.3.1 Parameters and Error Codes for the Inputs ........................................................... 20
4.3.2 Analog Inputs......................................................................................................... 21
4.3.2.1 Module Tab ........................................................................................................... 21
4.3.2.2 Tab AI 8 01 FS1000_1: Channels or AI 8 01 FS2000_1: Channels ................... 22
4.4 Configuring a Module Using ELOP II Factory ................................................... 22
4.4.1 Configuring the Inputs............................................................................................ 22
4.4.2 Signals and Error Codes for the Inputs.................................................................. 22
4.4.3 Analog Inputs......................................................................................................... 23

Table of Contents AI 8 01
Page 4 of 36 HI 800 195 E Rev. 1.00
5Operation .............................................................. 25
5.1 Handling................................................................................................................25
5.2 Diagnosis ..............................................................................................................25
6Maintenance.......................................................... 26
6.1 Faults.....................................................................................................................26
6.2 Maintenance Measures........................................................................................27
6.2.1 Loading the Operating System...............................................................................27
6.2.2 Proof Test...............................................................................................................27
7Decommissioning.................................................. 28
8Transport .............................................................. 29
9Disposal................................................................ 30
Appendix............................................................... 31
Glossary................................................................................................................31
Index of Figures....................................................................................................32
Index of Tables .....................................................................................................33
Index......................................................................................................................34

AI 8 01 1 Introduction
HI 800 195 E Rev. 1.00 Page 5 of 36
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 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 AI 8 01
Page 6 of 36 HI 800 195 E Rev. 1.00
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 Engineering
Manual
Project planning description for
HIMatrix systems
HI 800 101 E
SILworX Online Help Instructions on how to use SILworX -
ELOP II Factory Online
Help
Instructions on how to use ELOP II
Factory, Ethernet IP protocol,
INTERBUS protocol
-
First Steps
SILworX
Introduction to SILworX using the
HIMax system as an example
HI 801 103 E
First Steps
ELOP II Factory
Introduction to ELOP II Factory HI 800 006 E
Table 2: Additional Relevant Documents
The latest manuals can be downloaded from the HIMA website www.hima.com. The
revision index on the footer can be used to compare the current version of existing manuals
with the Internet edition.
1.2 Target Audience
This document addresses system planners, configuration engineers, programmers of
automation devices and personnel authorized to implement, operate and maintain the
modules and systems. Specialized knowledge of safety-related automation systems is
required.

AI 8 01 1 Introduction
HI 800 195 E Rev. 1.00 Page 7 of 36
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 AI 8 01
Page 8 of 36 HI 800 195 E Rev. 1.00
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.

AI 8 01 2 Safety
HI 800 195 E Rev. 1.00 Page 9 of 36
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
Enclosure 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 AI 8 01
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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.

AI 8 01 3 Product Description
HI 800 195 E Rev. 1.00 Page 11 of 36
3 Product Description
The AI 8 01 is a plug-in module with 8 analog inputs and is used for the modular F60
system. The inputs are galvanically isolated to the I/O BUS.
The module can be inserted in the F60 subrack's slot 3...8 as many times as required. Slots
1 and 2 are reserved for the power supply module and CPU 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 (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 module is equipped with safety-related analog inputs.
3.1.1 Safety-Related Analog Inputs
The analog inputs can be configured for 8 unipolar or 4 bipolar functions.
The module is intended to measure the voltage on the inputs.
To measure the current on the inputs, connect a resistor of up to 500 Ωin parallel to each
input. With smaller shunts, the measurement range is spread (less resolution), and zero
point errors increase by the spreading value.
The following input values are available:
Value range in the application
Input
channels
Polarity Current
Voltage FS10001) FS20001)
Safety-
related
accuracy
8 unipolar -10…+10 V -1000…[phone]…+2000 1 %
8 unipolar 0…20 mA 0…10003) 0…20003) 1 %
8 unipolar 0…20 mA 0…5002) 0…10002) 4 %
4 bipolar -10…+10 V -1000…[phone]…+2000 1 %
1) To specify when selecting the device type in the programming tool
2) with 250 Ωexternal shunt, HIMA no.: 00 0710251
3) with 500 Ωexternal shunt, HIMA no.: 00 0603501 (accuracy 0.05%, P1W)
Table 4: Input Values of the Analog Inputs
The module's value range can be configured to 1000-digit resolution (FS1000) or 2000-digit
resolution (FS2000), when the device type of the F60 modules (AI 8 01 FS1000 or AI 8 01
FS2000) is selected in the programming tool.
If an open-circuit occurs (the line is not monitored), any input signals are processed on the
high-resistance inputs. The value resulting from this fluctuating input voltage does not
correspond to the process values. With voltage inputs, the channels must thus be
terminated with a 10 kΩresistor. The internal source resistance must be taken into account
(≤500 Ω).
For a current measurement with the shunt connected in parallel, the 10 kΩresistor is not
required.
iUnused input channels must each be short-circuited to the ground (l-).
The max. permitted voltage between the analog terminals is ±13 V.

3 Product Description AI 8 01
Page 12 of 36 HI 800 195 E Rev. 1.00
The analog inputs are designed such that the measurement accuracy is maintained for 10
years. A recalibration must be carried out every 10 years.
3.1.1.1 Reaction in the Event of a Fault
If the module detects a fault on an analog input, the AI.Error Code system parameter > 0 is
set. In case of module faults, the Mod. Error Code system parameter > 0 is set.
In both cases, the device activates the ERR LED.
In addition to the analog value the error code must be evaluated. The analog value must be
configured to ensure a safety-related reaction.
The error code allows the user to configure additional fault reactions in the user program.
3.2 Equipment, Scope of Delivery
The following list specifies the available components and the corresponding part numbers:
Designation Description Part no.
AI 8 01 Plug-in module with 8 analog inputs 98 2200214
Table 5: Part Numbers
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

AI 8 01 3 Product Description
HI 800 195 E Rev. 1.00 Page 13 of 36
3.4 Assembly
The analog values are processed in parallel via two multiplexers and two analog/digital
converters with 12-bit resolution and the results are compared. This value is then made
available to the user program.
Additionally, test values are used by the existing digital/analog converters, converted back
to digital values, and then compared with the default value.
3.4.1 Block Diagram
I1 I8
1
2
44
3
5
ERR RUN
AD
AA
D
D
MUX MUX MUX
Analog Inputs
A/D Converter with 12-bit Resolution
Status Indicators
Logic
I/O Bus
Figure 2: Block Diagram

3 Product Description AI 8 01
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3.4.2 Front View
A
I 8
01
Figure 3: Front View

AI 8 01 3 Product Description
HI 800 195 E Rev. 1.00 Page 15 of 36
3.4.3 Status Indicators
LED Color Status Description
On Operating voltage presentRUN Green
Off No operating voltage
On Module fault and / or channel fault
Reaction as dictated by the diagnosis
ERR Red
Off No module faults and / or no channel faults
Table 6: Status Indicators
3.5 Product Data
General
Operating voltage 24 VDC, -15 %...+20 %, wss ≤15 %,
provided by a power supply unit with safe isolation
in accordance with IEC 61131-2 requirements.
Operating data 24 VDC / 380 mA
3.3 VDC / 150 mA
Ambient temperature 0 °C...+60 °C
Storage temperature -40 °C...+85 °C
Space requirement 6 RU, 4 HP
Weight 240 g
Table 7: Product Data
Analog inputs
Number of inputs 8 unipolar or 4 bipolar (galvanically isolated)
Nominal range 0...±10 V or
0...+20 mA (with shunt)
Operating range 0...±10.25 V or
0...+20.5 mA (with shunt)
Input resistance 1 MΩ
Digital resolution 12-bit
Source resistance input of
the input signal
≤500 Ω
Measurement accuracy at
25 °C, max.
±0.1 % of final value
Measurement accuracy on
full temperature range, max.
±0.5 % of final value
Temperature coefficient,
max.
±0.011 %/K of final value
Safety-related accuracy,
max.
±1 % of final value
Measured value refresh once per F60 cycle
Sampling time approx. 45 µs per channel
Table 8: Specifications for the Analog Inputs

4 Start-Up AI 8 01
Page 16 of 36 HI 800 195 E Rev. 1.00
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 F60 subrack of the modular HIMatrix F60 system.
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 rack
1. Insert the module as far as it can go – without jamming it – into the two guiding rails
which are located on the upper and lower part of the enclosure.
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 rack
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.

AI 8 01 4 Start-Up
HI 800 195 E Rev. 1.00 Page 17 of 36
4.1.2 Connection of the Analog Inputs
Only shielded cables with a length of a maximum of 300 m must be connected to the
analog inputs. Each analog input must be connected to a twisted pair of wires. The
shielding must be connected to the controller and the sensor housing and earthed of one
end to the controller side to form a Faraday cage.
Necessary shunts must be connected directly to the inputs of the module.
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 improper
connections.
Use the following terminals to connect the digital inputs:
Terminal Designation Function
1 I1+ Analog input 1
2 I- Ground input 1
3 I2+ Analog input 2
4 I- Ground input 2
5 I3+ Analog input 3
6 I- Ground input 3
7 I4+ Analog input 4
8 I- Ground input 4
9 Earth / shielding
Terminal Designation Function
10 I5+/I1- Analog input 5
11 I- Ground input 5
12 I6+/I2- Analog input 6
13 I- Ground input 6
14 I7+/I3- Analog input 7
15 I- Ground input 7
16 I8+/I4- Analog input 8
17 I- Ground input 8
18 Earth / shielding
Table 9: Terminal Assignment for the Analog Inputs
Unipolar inputs:
1+ and I-, I2+ and I-, I3+ and I-, I4+ and I-, … I8+ and I-
Bipolar inputs
I1+ and I5+/I1-, I2+ and I6+/I2-, I3+ and I7+/I3-, I4+ and I8+/I4-
All I- connections are interconnected.

4 Start-Up AI 8 01
Page 18 of 36 HI 800 195 E Rev. 1.00
4.1.3 Mounting the AI 8 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.
Special Conditions X
1. The F60 AI 8 01 module must be mounted in an enclosure, which fulfills the
requirements of the EN 60079-15 with the type of protection at least IP54, according to
EN 60529. Provide the device with the following label:
Work is only permitted in the de-energized state
Exception:
If a potentially explosive atmosphere has been precluded, work can be also performed
when the device is under voltage.
2 The enclosure in use must be able to safely dissipate the generated heat. The power
dissipation of the module is 12 W at maximum depending on the power supply voltage.
3. The HIMatrix AI 8 01 module must be supplied with 24 VDC 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 4: Label for Ex Conditions

AI 8 01 4 Start-Up
HI 800 195 E Rev. 1.00 Page 19 of 36
4.2 Configuration
The AI 8 01 module can be configured using a programming tool, SILworX or ELOP II
Factory. Which programming tool should be used depends on the revision status of the
operating system (firmware):
ELOP II Factory is required for operating system versions prior to 7.
SILworX is required for operating system version 7 and beyond.
iELOP II Factory is required to load a new operating system (version 7 or beyond) into a
controller with a CPU operating system version prior to 7. SILworX is then required once
the loading procedure is completed.
4.2.1 Module Slots
Slots 1 and 2 on the F60 module rack are reserved for the PS 01 power supply module and
CPU module, respectively. Any type of I/O modules can be plugged in to slots 3...8.
The module slots in SILworX and ELOP II Factory are numbered as follows:
Module Slot on the rack Slot in SILworX Slot in ELOP II
Factory
PS 01 1 - -
CPU/COM 2 0/1 -
I/O 3 2 1
I/O 4 3 2
I/O 5 4 3
I/O 6 5 4
I/O 7 6 5
I/O 8 7 6
Table 10: Module Slots
i
The PS 01 power supply module is not configured.
CPU and COM are both on the F 60 CPU 01 module. In the programming tools,
however, they are represented as separated items.

4 Start-Up AI 8 01
Page 20 of 36 HI 800 195 E Rev. 1.00
4.3 Configuring a Module with SILworX
In the Hardware Editor, the controller is represented with the following modules:
one processor module (CPU)
one communication module
6 slots available for I/O modules
To insert I/O modules, drag them from the module list onto an available slot.
Two variants are available for the AI 8 01 module:
AI 8 01 FS1000: Resolution of the analog value -1000…+1000 (-10 V…+10 V)
AI 8 01 FS2000: Resolution of the analog value -2000…+2000 (-10 V…+10 V)
Double-click the module to open the Detail View with the corresponding tabs. The tabs are
used to assign the global variables configured in the user program to the system
parameters of the corresponding module.
4.3.1 Parameters and Error Codes for the Inputs
The following tables specify the system parameters that can be read and set for the inputs,
including the corresponding error codes.
In the user program, the error codes can be read using the variables assigned within the
logic.
The error codes can also be displayed in SILworX.