HIMA HIMatrix User manual

HIMatrix
Safety-Related Controller
DO 8 01 Manual
HIMA Paul Hildebrandt GmbH + Co KG
Industrial Automation
Rev. 1.00 HI 800 207 E

HI 800 207 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
Revisions
technical editorial
1.00 Added: Configuration with SILworX X X

DO 8 01 Table of Contents
HI 800 207 E Rev. 1.00 Page 3 of 34
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 Digital Outputs............................................................................... 11
3.1.1.1 Reaction in the Event of a Fault............................................................................. 11
3.2 Equipment, Scope of Delivery............................................................................ 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 Status Indicators .................................................................................................... 15
3.4.4 I/O LEDs ................................................................................................................ 15
3.5 Product Data......................................................................................................... 15
4Start-Up................................................................. 17
4.1 Installation and Mounting ................................................................................... 17
4.1.1 Mounting and Removing the Modules ................................................................... 17
4.1.2 Connecting the Relay Outputs............................................................................... 18
4.2 Configuration ....................................................................................................... 19
4.2.1 Module Slots .......................................................................................................... 19
4.3 Configuring the Module with SILworX............................................................... 19
4.3.1 Parameters and Error Codes for the Output .......................................................... 20
4.3.2 Digital outputs ........................................................................................................ 20
4.3.2.1 Module Tab ........................................................................................................... 20
4.3.2.2 DO 8 01_1: Channels Tab .................................................................................... 21
4.4 Configuring a Module Using ELOP II Factory ................................................... 21
4.4.1 Configuring the Outputs......................................................................................... 21
4.4.2 Signals and Error Codes for the Output................................................................. 21
4.4.3 Digital outputs ........................................................................................................ 22

Table of Contents DO 8 01
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5Operation .............................................................. 23
5.1 Handling................................................................................................................23
5.2 Diagnosis ..............................................................................................................23
6Maintenance.......................................................... 24
6.1 Faults.....................................................................................................................24
6.2 Maintenance Measures........................................................................................25
6.2.1 Loading the Operating System...............................................................................25
6.2.2 Proof Test...............................................................................................................25
7Decommissioning.................................................. 26
8Transport .............................................................. 27
9Disposal................................................................ 28
Appendix............................................................... 29
Glossary................................................................................................................29
Index of Figures....................................................................................................30
Index of Tables .....................................................................................................31
Index......................................................................................................................32

DO 8 01 1 Introduction
HI 800 207 E Rev. 1.00 Page 5 of 34
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 DO 8 01
Page 6 of 34 HI 800 207 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.

DO 8 01 1 Introduction
HI 800 207 E Rev. 1.00 Page 7 of 34
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 DO 8 01
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1.3.2 Operating Tips
Additional information is structured as presented in the following example:
iThe text corresponding to the additional information is located here.
Useful tips and tricks appear as follows:
TIP The tip text is located here.

DO 8 01 2 Safety
HI 800 207 E Rev. 1.00 Page 9 of 34
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 DO 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.

DO 8 01 3 Product Description
HI 800 207 E Rev. 1.00 Page 11 of 34
3 Product Description
Do 8 01 is a plug-in module with 8 outputs for the modular F60 HIMatrix system.
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 plug-in module is equipped with safety-related relay outputs.
3.1.1 Safety-Related Digital Outputs
The relay status is indicated by the 8 LEDs located on the front plate, above the terminator
plugs.
Each relay output is equipped with 2 safety relays with forcibly guided contacts and a
standard relay. An internal fuse is used to limit the output contacts' switching current to
60% (3.15 A) of the maximum permissible value (in accordance with VDE 0116, EN 298).
The contact outputs can be used for safety shutdowns.
To connect direct-current voltages, an external fuse able to handle the maximum
permissible current must be added to the contact circuit.
The air and creeping distances are designed in accordance with IEC 61131-2 for
overvoltage class II up to 300 V.
For module applications in accordance with EN 298, a temperature range of 0...60 °C is
required. To this end, the supply voltage must be limited to 24 VDC / -10...-2.5 %.
iWith safety-related applications, the relay module must be rebuilt every 3 years (proof test,
see IEC/EN 61508-4, Section 3.8.5).
3.1.1.1 Reaction in the Event of a Fault
If the module detects a faulty signal on a digital output, the affected module output is set to
the safe (de-energized) state using the safety switches.
If a fault in the module occurs, all digital outputs are switched off.
In both cases, the module activates the FAULT LED.
The error code allows the user to configure additional fault reactions in the user program.
If communication is lost, the output is set to the initial value configured. This effect must be
taken into account for the behavior of the connected output.
3.2 Equipment, Scope of Delivery
The following list specifies the available components and the corresponding part numbers:
Designation Description Part no.
DO 8 01 Plug-in module with 8 relay outputs. 98 2200112
Table 4: Part Numbers

3 Product Description DO 8 01
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3.3 Type Label
The type plate contains the following details:
Product name
Bar code (1D or 2D code)
Part no.
Production year
Hardware revision index (HW Rev.)
Firmware revision index (FW Rev.)
Operating voltage
Mark of conformity
Figure 1: Sample Type Label

DO 8 01 3 Product Description
HI 800 207 E Rev. 1.00 Page 13 of 34
3.4 Assembly
This chapter describes the layout and function of the plug-in module.
3.4.1 Block Diagram
I/O Bus
Status Indicators
8 Relay Outputs
Figure 2: Block Diagram

3 Product Description DO 8 01
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3.4.2 Front View
RUN ERR
1
2
3
4
5
6
7
8
1
21
3
42
5
63
7
84
9
10 5
11
12 6
13
14 7
15
16 8
DO 8
01
Figure 3: Front View

DO 8 01 3 Product Description
HI 800 207 E Rev. 1.00 Page 15 of 34
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 corresponding channel is active (energized)1...8 Yellow
Off The corresponding channel is inactive (de-energized)
Table 6: I/O LEDs
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 3.3 VDC / 0.2 A
24 VDC, ±10 % 1) / 0.7 A
24 VDC / -10...-2.5 % 2) / 0.7 A
Ambient temperature 0°C…+50 °C 1)
0°C...+60 °C 2)
Storage temperature -40 °C...+85 °C
Space requirement 6 RU, 4 HP
Weight 300 g
1) Caution: Restricted system data!
2) Caution: With applications in accordance with EN 298
Table 7: Product Data

3 Product Description DO 8 01
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Relay outputs
Number 8 potential-free normally open contact
Execution 2 safety relays with forcibly guided contacts,
1 standard relay
Switching voltage ≥6 V, ≤250 VAC / 250 VDC
Switching current ≥10 mA, ≤3 A
internally fused with 3.15 A
fuse breaking capacity: 100 A
Switching capacity AC TÜV:
max. 400 VA, cos ϕ≥0.5, max. 250 VAC
max. 600 VA, cos ϕ= 1, max. 250 VAC
Switching capacity DC
(induction free)
UL:
30 VDC at 3 A with ohmic load
60 VDC at 0.3 A with ohmic load
TÜV:
Up to 30 VDC: max. 90 W (3.15 A)
Up to 70 VDC: max. 35 W (0.5 A)
Up to 127 VDC:max. 40 W (0.315 A)
Up to 250 VDC:max. 60 W (0.25 A)
(adapt external fuse)
Type of protection IP40
Contact material Silver alloy, flash plated
Switching time approx. 30 ms
Reset time approx. 20 ms
Bounce time approx. 30 ms
Product life
mechanical
electrical
≥3 x 106switching operations
≥2.5 x 105switching operations at ohmic full load and ≤0.1
switching operations per second
Table 8: Specifications for the Relay Outputs

DO 8 01 4 Start-Up
HI 800 207 E Rev. 1.00 Page 17 of 34
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.
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.

4 Start-Up DO 8 01
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4.1.2 Connecting the Relay Outputs
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 output contacts are connected in pairs using connectors with numbered terminals. The
terminal pins on the front plate of the module have the same numbered sequence to avoid
improper connections.
The terminal connections comply with IP20 protection requirements. With higher
requirements, an enclosure with suitable type of protection must be used for the F60.
If voltages other than SELV and PELV are connected, suitable cables with double or
increased insulation must be used, e.g., power cables.
The relay outputs are connected as follows:
Terminal Designation Function
1 Contact 1, terminal A
2 1 Contact 1, terminal B
3 Contact 2, terminal A
4 2 Contact 2, terminal B
5 Contact 3, terminal A
6 3 Contact 3, terminal B
7 Contact 4, terminal A
8 4 Contact 4, terminal B
9 Contact 5, terminal A
10 5 Contact 5, terminal B
11 Contact 6, terminal A
12 6 Contact 6, terminal B
13 Contact 7, terminal A
14 7 Contact 7, terminal B
15 Contact 8, terminal A
16 8 Contact 8, terminal B
Table 9: Terminal Assignment for the Relay Outputs

DO 8 01 4 Start-Up
HI 800 207 E Rev. 1.00 Page 19 of 34
4.2 Configuration
The DO 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.
4.3 Configuring the Module with SILworX
In the Hardware Editor, the controller is represented with the following modules:
one processor module (CPU)
one communication module (COM)
6 slots available for I/O modules
To insert I/O modules, drag them from the module list onto an available slot.
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 Start-Up DO 8 01
Page 20 of 34 HI 800 207 E Rev. 1.00
4.3.1 Parameters and Error Codes for the Output
The following tables specify the system parameters that can be read and set for the
outputs, 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.
4.3.2 Digital outputs
The following tables present the statuses and parameters for the output module in the
same order as given in the Hardware Editor.
4.3.2.1 Module Tab
The Module tab contains the following system parameters.
System
parameter
Data
type
R/W Description
DO.Error Code WORD R Error codes for all digital outputs
Coding Description
0x0001 Module fault
0x0002 MOT test safety switch 1 faulty
0x0004 MOT test safety switch 2 faulty
0x0008 FTT test of test pattern faulty
0x0010 MOT test of the read back channels faulty
0x0020 MOT test active shutdown faulty
0x0040 Relay status fault detected during initialization
0x0100 FTT test of CS (chip select) signals faulty
0x0400 FTT test: 1st temperature threshold exceeded
0x0800 FTT test: 2nd Temperature threshold
exceeded
0x1000 FTT test: Monitoring of auxiliary voltage 1:
Low voltage
0x2000 MOT test: status of safety switches
0x4000 MOT test: active shutdown via watchdog
returns a fault
Module Error
Code
WORD R Error codes for the module
Coding Description
0x0000 I/O processing, if required with errors
0x0001 No I/O processing (CPU not in RUN)
0x0002 No I/O processing during the booting test
0x0004 Manufacturer interface operating
0x0010 No I/O processing: wrong configuration
0x0020 No I/O processing: fault rate exceeded
0x0040/
0x0080
No I/O processing: configured module not
plugged in
Module SRS UDINT R Slot number (System.Rack.Slot)
Module Type UINT R Type of module, target value: 0xF906 [63750dec]
Table 11: SILworX - System Parameters for Digital Outputs, Module Tab