Himax X-DO 24 02 User manual

X-DO 24 02
HIMax®
Digital Output Module
Manual

HI 801 095 E Rev. 4.00 (1117)
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 2011, 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
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Type of Change
Revision
index
Revisions
technical editorial
3.01 Revised: Lead marking of the system cable, inductive load X X
4.00 New edition for SILworX V4 X X

X-DO 24 02 Table of Contents
HI 801 095 E Rev. 4.00 Page 3 of 54
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 Block Diagram........................................................................................................ 13
3.4.2 Indicators ............................................................................................................... 14
3.4.3 Module Status Indicators ....................................................................................... 15
3.4.4 System Bus Indicators ........................................................................................... 16
3.4.5 I/O Indicators.......................................................................................................... 16
3.5 Product Data......................................................................................................... 17
3.6 Connector Boards................................................................................................ 19
3.6.1 Mechanical Coding of Connector Boards .............................................................. 19
3.6.2 Coding of X-CB 010 Connector Boards ................................................................. 20
3.6.3 Connector Boards with Screw Terminals............................................................... 21
3.6.4 Terminal Assignment for Connector Boards with Screw Terminals....................... 22
3.6.5 Connector Boards with Cable Plug ........................................................................ 24
3.6.6 Pin Assignment for Connector Boards with Cable Plug......................................... 25
3.7 System Cable X-CA 010....................................................................................... 26
3.7.1 Cable Plug Coding................................................................................................. 27

Table of Contents X-DO 24 02
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4Start-up ................................................................. 28
4.1 Mounting ...............................................................................................................28
4.1.1 Wiring Outputs not in Use ......................................................................................28
4.2 Mounting and Removing the Module.................................................................. 29
4.2.1 Mounting a Connector Board .................................................................................29
4.2.2 Mounting and Removing the Module......................................................................31
4.3 Line Monitoring (SC/OC)...................................................................................... 33
4.3.1 Recommended Values for Line Monitoring (SC/OC).............................................. 33
4.4 Configuring the Module in SILworX.................................................................... 34
4.4.1 Tab: Module ...........................................................................................................35
4.4.2 Tab: I/O Submodule DO24_02...............................................................................36
4.4.3 Tab: I/O Submodule DO24_02: Channels.............................................................. 37
4.4.4 Submodule Status [DWORD] .................................................................................38
4.4.5 Diagnostic Status [DWORD]...................................................................................39
4.5 Connection Variants.............................................................................................40
4.5.1 Wiring Actuators .....................................................................................................40
4.5.2 Redundant Wiring of Actuators via Two Modules...................................................41
4.5.3 Wiring Inductive Loads ........................................................................................... 42
4.5.4 Wiring Actuators via Field Termination Assembly ..................................................43
5Operation .............................................................. 44
5.1 Handling ................................................................................................................44
5.2 Diagnosis ..............................................................................................................44
6Maintenance .......................................................... 45
6.1 Maintenance Measures ........................................................................................45
6.1.1 Loading the Operating System...............................................................................45
6.1.2 Proof Test...............................................................................................................45
7Decommissioning .................................................. 46
8Transport .............................................................. 47
9Disposal ................................................................ 48
Appendix ............................................................... 50
Glossary ................................................................................................................50
Index of Figures.................................................................................................... 51
Index of Tables .....................................................................................................52
Index ......................................................................................................................53

X-DO 24 02 1 Introduction
HI 801 095 E Rev. 4.00 Page 5 of 54
1 Introduction
The present 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 HIMax 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.
HIMax
System manual
Hardware description of the
HIMax system
HI 801 001 E
HIMax
Safety manual
Safety functions of the HIMax
system
HI 801 003 E
HIMax
Communication manual
Description of communication
and protocols
HI 801 101 E
SILworX Online Help
(OLH)
Instructions on how to use
SILworX
-
First Steps Introduction to SILworX HI 801 103 E
Table 1: Additional Relevant Manuals
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
devices and systems. Specialized knowledge of safety-related automation systems is
required.

1 Introduction X-DO 24 02
Page 6 of 54 HI 801 095 E Rev. 4.00
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 SILworX.
Italics: System parameter and 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.
NOTICE
Type and source of damage!
Damage prevention
SIGNAL WORD
Type and source of danger!
Consequences arising from the danger
Danger prevention

X-DO 24 02 1 Introduction
HI 801 095 E Rev. 4.00 Page 7 of 54
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.

2 Safety X-DO 24 02
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2 Safety
All safety information, notes and instructions specified in this manual must be strictly
observed. The product may only be used if all guidelines and safety instructions are
adhered to.
This product is operated in accordance with SELV or PELV. No imminent danger results
from the module itself. The use in Ex-Zone is permitted if additional measures are taken.
2.1 Intended Use
HIMax components are designed for assembling safety-related controller systems.
When using the components in the HIMax 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 HIMax system to environmental conditions other than those specified in this
manual can cause the HIMax 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 modules.
NOTE
Device damage due to electrostatic discharge!
When performing the work, make sure that the working area 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.

X-DO 24 02 2 Safety
HI 801 095 E Rev. 4.00 Page 9 of 54
2.2 Residual Risk
No imminent danger results from a HIMax module 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 HIMax controller is a part of the safety equipment of a system. If the controller fails, the
system adopts the safe state.
In case of emergency, no action that may prevent the HIMax systems from operating safely
is permitted.

3 Product Description X-DO 24 02
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3 Product Description
The X-DO 24 02 digital output module is intended for use in the programmable electronic
system (PES) HIMax.
The module can be inserted into any of the base plate slots with the exception of the slots
reserved for system bus modules. For more information, see System Manual
(HI 801 001 E).
The module is equipped with 24 digital outputs that are operated with 24 or 48 VDC
external power supply. Each output can be loaded up to a nominal current of 0.5 A; ensure
that the total permissible current of the external voltage supply does not exceeded 12 A.
The outputs are suitable for connecting ohmic, inductive and capacitive loads and lamps.
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).
Refer to the HIMax Safety Manual (HI 801 003 E) for more information on the standards
used to test and certify the module and the HIMax system.
3.1 Safety Function
The module ensures its safety function using three safety switches connected in series for
each channel. This ensures that each output is two-fault-tolerant with respect to the safety
switch. Each safety switch of a channel can be individually switched off either via the
system bus (I/O bus) or via the second independent shutdown function (watchdog).
The safe output state is the de-energized state. Redundant processor systems monitor the
values expected for the outputs. Outputs that do not correspond to the expected values are
reset. One of the two read-back branches that were monitored for their expected values
can be tested.
The safety function is performed in accordance with SIL 3.
3.1.1 Reaction in the Event of a Fault
If a fault is detected, the module adopts the safe state and all the outputs are de-energized
in accordance with the 'de-energize to trip principle'. If a channel fault occurs, only the
corresponding output is switched off; if a module fault occurs, all module outputs are
switched off.
If the system bus fails, the outputs are de-energized.
The module activates the Error LED on the front plate.
3.2 Scope of Delivery
The module must be installed on a suitable connector board to be able to operate. If a FTA
is used, a system cable is required to connect the connector board to the FTA. Connector
boards, system cables and FTAs are not included within the scope of delivery.
The connector boards are described in Chapter 3.6, the system cables are described in
Chapter 3.7. The FTAs are described in own manuals.

X-DO 24 02 3 Product Description
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3.3 Type Label
The type label specifies the following important details:
Product name
Mark of conformity
Bar code (2D or 1D code)
Part number (Part-No.)
Hardware revision index (HW Rev.)
Software revision index (SW Rev.)
Operating voltage (Power)
Ex specifications (if applicable)
Production year (Prod-Year:)
Figure 1: Sample Type Label

3 Product Description X-DO 24 02
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3.4 Structure
The module is equipped with 24 digital outputs. The output are operated with 24 V or 48 V
external power, while the module is supplied with power via the base plate. The external
and internal power supplies are galvanically isolated from one another.
The module comes with line monitoring (SC/OC). If the open-circuit monitoring is
configured in SILworX, see Chapter 4.3, the channels are automatically checked for open-
circuits (OC) and short-circuits (SC).
The outputs are protected against overload. If an overload is detected, the corresponding
output is switched off and switched on again after five seconds. If the overload is still
present, the output is switched off again for five seconds. This process is repeated as long
as the overload is present. If the cyclic switch-on after overload must be prevented, the
user program must be configured accordingly.
The total current allowed for the external power supply is 12 A.
The safety-related 1oo2 processor system for the I/O module controls and monitors the I/O
level. The data and states of the I/O module are made available to the processor modules
via the redundant system bus. The system bus has a redundant structure for reasons of
availability. Redundancy is only ensured if both system bus modules are inserted in the
base plates and configured in SILworX.
The module is equipped with LEDs to indicate the status of the digital outputs, see
Chapter 3.4.2.

X-DO 24 02 3 Product Description
HI 801 095 E Rev. 4.00 Page 13 of 54
3.4.1 Block Diagram
The following block diagram illustrates the structure of the module.
System Busses
Safety-Related Processor System
Interface
External Power Supply
Figure 2: Block Diagram

3 Product Description X-DO 24 02
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3.4.2 Indicators
The following figure shows the LED indicators for the module.
Figure 3: Indicators

X-DO 24 02 3 Product Description
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The LEDs indicate the operating state of the output module.
The LEDs on the module are divided into three groups:
Module status indicators (Run, Error, Stop, Init)
System bus indicators (A, B)
I/O indicators (DO 1...24, Field)
When the supply voltage is switched on, a LED test is performed and all LEDs briefly flash
simultaneously.
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: Flashing in sync with data transfer
Table 3: Blinking Frequencies of LEDs
3.4.3 Module Status Indicators
These LEDs are located on the front plate, on the upper part of the module.
LED Color Status Description
On Module in RUN, normal operation
Blinking1 Module state:
STOP/OS_DOWNLOAD or
OPERATE (only with processor modules)
Run Green
Off Module not in RUN,
observe the other status LEDs
On/Blinking1 Internal module faults detected by self-tests, e.g.,
hardware, software or voltage supply.
Fault while loading the operating system
Error Red
Off Normal operation
On Module state:
STOP / VALID CONFIGURATION
Blinking1 Module state:
STOP / INVALID CONFIGURATION or
STOP / OS_DOWNLOAD
Stop Yellow
Off Module not in STOP, observe the other status LEDs
On Module state: INIT, observe the other status LEDs
Blinking1 Module state: LOCKED, observe to the other status
LEDs
Init Yellow
Off Module state: neither INIT nor LOCKED, observe
the other status LEDs
Table 4: Module Status Indicators

3 Product Description X-DO 24 02
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3.4.4 System Bus Indicators
The system bus LEDs are labeled Sys Bus.
LED Color Status Description
On Physical and logical connection to the system bus
module in slot 1.
Green
Blinking1 No physical connection to the system bus module in
slot 1.
A
Yellow Blinking1
The physical connection to the system bus module
in slot 1 has been established.
No connection to a (redundant) processor module
running in system operation.
On Physical and logical connection to the system bus
module in slot 2.
Green
Blinking1 No physical connection to the system bus module in
slot 2.
B
Yellow Blinking1
The physical connection to the system bus module
in slot 2 has been established.
No connection to a (redundant) processor module
running in system operation.
A+B Off Off Neither physical nor logical connection to the
system bus modules in slot 1 and slot 2.
Table 5: System Bus Indicators
3.4.5 I/O Indicators
The LEDs of the I/O indicators are labeled Channel.
LED Color Status Description
On The related channel is active (energized).
Blinking2 The related channel is faulty.
Channel
1…24
Yellow
Off The related channel is inactive (de-energized).
Blinking2 Field fault on at least one channel, e.g., open-
circuit, short-circuit, over-current, etc.
Field Red
Off No field fault displayed!
Table 6: I/O LEDs

X-DO 24 02 3 Product Description
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3.5 Product Data
General
Supply voltage 24 VDC, -15 %...+20 %, rP≤5 %
PELV, SELV
Current input min. 0.5 A (idle)
Continuous load through external
power supply
max. 12 A at 24 VDC
Electrical isolation Yes, between supply voltage and outputs (ext.
power supply)
Operating temperature 0…+60 °C
Storage temperature -40…+85 °C
Humidity max. 95 % relative humidity, non-condensing
Type of protection IP20
Dimensions (H x W x D) 310 x 29.2 x 230 mm
Weight approx. 1.1 kg
Table 7: Product Data
Figure 4: Views of X-DO 24 02

3 Product Description X-DO 24 02
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Digital Outputs
Number of outputs (number of channels) 24, non-galvanically isolated
External supply voltage 24/48 VDC, -15 %...+20 %, rP≤5 %
PELV, SELV
Output voltage External supply voltage
minus internal voltage drop
Voltage drop (with high level) 1.3 V at 0.75 A output current
Nominal rated current (with high level) 0.5 A, range 0.01...0.6 A
Total current permitted for the module max. 12 A
Leakage current (with low level) max. 500 µA
Current limiting in the event of short-circuit 2 A
Overcurrent interruption I > 0.75 A for t > 50 ms
Ohmic load To nom. rated current 0.5 A
Inductive load max. 1 H
Lamp load (24 V lamps) max. 4 W
Capacitive load max. 100 µF
Line monitoring
OC Limit ≤5 mA (24 V), ≤2 mA (48 V)
SC Limit > 0.75 A (range 0.75...0.8 A)
Overload protection of the outputs,
transient
60 V (max. 73 V)
Switching time of the channels (with ohmic
load)
100 µs
Test impulse (with ohmic load) typ. 200 µs
Behavior upon overload The affected output is switched off and re-
started cyclically.
Table 8: Specifications for the Digital Outputs

X-DO 24 02 3 Product Description
HI 801 095 E Rev. 4.00 Page 19 of 54
3.6 Connector Boards
A connector board connects the module to the field zone. Module and connector board
form together a functional unit. Insert the connector board into the appropriate slot prior to
mounting the module.
The following connector boards are available for the module:
Connector board Description
X-CB 010 01 Connector board with screw terminals
X-CB 010 02 Redundant connector board with screw terminals
X-CB 010 03 Connector board with cable plug
X-CB 010 04 Redundant connector board with cable plug
Table 9: Available Connector Boards
3.6.1 Mechanical Coding of Connector Boards
I/O modules and connector boards are mechanically coded starting from hardware revision
AS10 to prevent them from being equipped with improper I/O modules. Coding avoids
incorrect installation of improper I/O modules thus preventing negative effects on redundant
modules and field zone. A part from that, improper equipment has no effect on the HIMax
system since only I/O modules that are correctly configured in SILworX enter the RUN
state.
I/O modules and the corresponding connector boards have a mechanical coding in form of
wedges. The coding wedges in the female connector of the connector board match with the
male connector recesses of the I/O module plug, see Figure 5.
Coded I/O modules can only be plugged in to the corresponding connector boards.

3 Product Description X-DO 24 02
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Male Connector Recess
Prepared Male Connector Recess
Coding Wedge
Guideway for Coding Wedge
Figure 5: Coding Example
Coded I/O modules can be plugged in to uncoded connector boards. Uncoded I/O modules
cannot be plugged in to coded connector boards.
3.6.2 Coding of X-CB 010 Connector Boards
a7 a13 a20 a26 c7 c13 c20 c26
X X X X
Table 10: Position of Coding Wedges