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2 Safety

HIMax System

HI 801 001 E Rev. 4.01

Page 14 of 122

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.

Содержание HIMax

Страница 1: ...SYSTEM HIMax System Manual...

Страница 2: ...A 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...

Страница 3: ...se Plate Structure 17 3 1 2 Ventilation 18 3 1 3 Monitoring the Temperature 18 3 1 4 Power Supply 18 3 2 System Bus 19 3 2 1 System Bus with Line Structure 21 3 2 2 System Bus with Network Structure 2...

Страница 4: ...es in a Project 49 5 2 1 Types of Variables 49 5 2 2 Initial Value 50 5 2 3 System Variables and System Parameters 50 5 2 4 Assignment to I O Channels 61 5 2 5 Assignment to Communication Connections...

Страница 5: ...ations Dimensioning 91 9 Lifecycle 92 9 1 Installation 92 9 1 1 Mechanical Structure 92 9 1 2 Connecting the Field Zone to the I O Module 92 9 1 3 Earthing 96 9 1 4 Electrical Connections 101 9 1 5 Mo...

Страница 6: ...Table of Contents HIMax System HI 801 001 E Rev 4 01 Page 6 of 122 Index of Figures 118 Index of Tables 119 Index 121...

Страница 7: ...lation Start up Service and maintenance HIMax Documentation and Support Overview of the documentation and on how to get access to the support Appendix Configuration examples for the HIMax systems Glos...

Страница 8: ...ked 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 dang...

Страница 9: ...ge 9 of 122 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 trick...

Страница 10: ...ergize to trip principle A system that operates in accordance with the de energize to trip principle does not require any power to perform its safety function Thus if a fault occurs the input and outp...

Страница 11: ...rd IP20 IP00 If required by the relevant application standards e g EN 60204 the device must be installed in an enclosure of the specified protec tion class e g IP54 Table 2 General requirements Climat...

Страница 12: ...2 GHz 80 AM RFI test 3 V m 2 GHz 3 GHz 80 AM RFI test 20 V m 80 MHz 1 GHz 80 AM 20 V m IEC EN 61000 4 4 Burst test Power lines 2 kV and 4 kV Signal lines 2 kV 4 kV 2 kV IEC EN 61000 4 12 Damped oscil...

Страница 13: ...ith knowledge of ESD protective measures may modify or extend the system or replace a module NOTE Electrostatic discharge can damage the electronic components within the control lers When performing t...

Страница 14: ...quirements 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 sa...

Страница 15: ...Ethernet cables are used to interconnect the base plates The controller can be easily adapted to future extensions of the process to be controlled e g by adding modules or base plates containing modu...

Страница 16: ...al racks are extension racks Among these rack 1 may contain one or two processor modules The remaining racks must contain no processor modules Rack 0 can be extended with up to 15 extension racks Cabl...

Страница 17: ...1 Base Plate Structure Hook in rail with slot number Backplane Bus Connector for 24 VDC module power supply here slot number 9 Connector for connecting the system bus to a module here slot number 9 Gu...

Страница 18: ...an racks are equipped with 2 3 or 4 fans For more information refer to the X FAN Manual HI 801 033 E Additional dissipation of the generated hot air must be ensured see Chapter 9 1 6 3 1 3 Monitoring...

Страница 19: ...lculation of the power required use the power consumption values of the individual modules as specified in the corresponding manuals The power consumption values of the other consumer loads are specif...

Страница 20: ...Ethernet connections Therefore the RJ 45 sock ets UP and DOWN and DIAG may only be used to connect to HIMax racks Do not connect the sockets UP and DOWN and DIAG to local networks or other de vices wi...

Страница 21: ...The extension rack connected to the UP socket of rack 0 has rack ID 1 All additional racks connected to rack 0 through rack 1 have uneven rack IDs up to 15 The extension base plate connected to the D...

Страница 22: ...rack ID can be almost freely assigned in the network structure It is however required that the redundant processor modules are inserted in rack 0 and 1 The racks 0 and 1 must be directly connected to...

Страница 23: ...HIMax System 3 Product Description HI 801 001 E Rev 4 01 Page 23 of 122 Figure 4 System Bus with Network Structure...

Страница 24: ...The HIMax system can thus stretch across an extensive production line or pipeline s length All used components must allow a data rate of 1 GB s Fiber optic cables are suitable for extending Ethernet...

Страница 25: ...respective on whether the line or network structure has been set up System Bus Extension for the Max Latency Default Settings Already if the maximum system bus latency is set to the default value 0 th...

Страница 26: ...le length max 50 s 1 s The following formula applies to the delay due to the fiber optic cable and its length 49 s length 5 s km i e length 9 800 m The same formula applies to the length between proce...

Страница 27: ...The maximum delay must be 50 s 10 s 40 s It is composed of the delay due to both converters 1 s and the delay due to the fiber optic cable max 39 s The following formula applies to the delay due to th...

Страница 28: ...able latency See below tSwitch Y Switch Y latency 5 s tCu2 Copper cable latency between rack B and switch Y See below tMessage Runtime for 1 GBit s message consid ered 1 time for each route 6 592 s Th...

Страница 29: ...ted in the specifications or must be determined through a measurement and then be used in the calculation i When designing the network structure and calculating the maximum latency HIMA recommends to...

Страница 30: ...Connected to Port 5 of Switch A Rack 14 Connected to Port 3 of Switch C Rack 15 Connected to Port 4 of Switch A Switch C Hirschmann SPIDER II Giga 5T 2S EEC Rail Switch with Port Num ber Switch B Hirs...

Страница 31: ...rack 0 With respect to the type and number of the network components this corresponds to the connections between rack 6 9 or 12 and rack 0 Connection between rack 15 and rack 0 With respect to the typ...

Страница 32: ...be made The maximum latency allowed between processor and communication modules is 305 s in accordance with Table 8 The latency between rack 0 and rack 8 is calculated as follows tLatency 3 tCu tSwit...

Страница 33: ...ds The connector between I O modules and the corresponding connector boards are mechanically coded This ensures that a module of a certain type can only be plugged in to the corresponding connector bo...

Страница 34: ...the following slots Slots 3 to 6 on rack 0 Slots 3 to 4 on rack 1 3 Slot 5 on rack 0 and slot 4 on rack 1 may not simultaneously contain processor modules 4 Slot 6 on rack 0 and slot 3 on rack 1 may n...

Страница 35: ...ls the user programs running in a processor module 3 4 1 Operating System Tasks Controlling the cyclic run of the user programs Performing the self tests of the module Controlling safety related commu...

Страница 36: ...configuration is available in the memory From the LOCKED state Setting the mode switch to Stop if one single processor mod ule exists STOP OS_DOWNLO AD Processor module stopped The operating system is...

Страница 37: ...modules are included or not in the configuration If additional base plates with 20 or more modules are connected during operation this can cause the watchdog time to be exceeded 3 4 2 Behavior in the...

Страница 38: ...nfigure noise blanking in accordance with the following examples Example 11 2 32 Safety time ms 600 2000 1000 Watchdog time ms 200 500 500 Cycle time ms 100 200 200 Max noise blanking time ms 200 1000...

Страница 39: ...irectly upon completion of the read in process If the interference is still present in the following cycle during the read in process the module detects the interference and the system decides if nois...

Страница 40: ...e interference and the system decides if noise blanking can be performed at this point in time based on the following rule Safety time elapsed time 2 watchdog time 0 Noise blanking is possible in the...

Страница 41: ...vated see the input module manuals Noise blanking on the system bus is always active and cannot be deactivated in SILworX Effective Direction from the Processor Module to the Output Module Noise blank...

Страница 42: ...IMax differentiate between Boolean and scalar events Boolean Events Changes of Boolean variables e g of digital inputs Alarm and normal state They can be arbitrarily assigned to the variable states Sc...

Страница 43: ...or module and SOE module was terminated System events contain the SRS identifier of the module causing the events Status Variables Status variables provide the user program with the state of scalar ev...

Страница 44: ...the HIMA website using the system ID of the controller e g 60000 To do so follow the instructions on the HIMA website www hima com Products Registration Communication Options SILworX i The software a...

Страница 45: ...HI 801 101 E For the network structure function of the HIMax systems a license must be purchased from HIMA To activate the function HIMA provides a license code which must be entered with the PADT in...

Страница 46: ...able e g because a module failed or was removed Safety related operation is also ensured if several processor modules fail 4 1 2 Upgrading Redundancy If a new processor module is added to a running HI...

Страница 47: ...ector board once only Specific connector boards can be also provided for the threefold redundant implementation of certain I O modules In such a case the user program must manage the redundancy For mo...

Страница 48: ...for the redundant power supply unit Each module supports internal decoupling of the operating voltage from the two terminals A redundant supply external to the HIMax system must be provided for conne...

Страница 49: ...rfaces only crossover cables may be used 5 2 Using Variables in a Project A variable is a placeholder for a value within the program logic The variable name is used to symbolically address the storage...

Страница 50: ...le derived its value Examples Physical input Communication interface User program in the STOP state The value that the connected variables should adopt can be set for safeethernet and communication pr...

Страница 51: ...eneral System variables for configuring the controller see Table 17 System variables providing information seeTable 18 Hardware Modules See the manual of the corresponding module type The system varia...

Страница 52: ...et Cycle Time Mode Autostart Global Forcing Allowed Global Force Timeout Reaction Load Allowed Reload Allowed Start Allowed OFF The parameters cannot be changed during operation Main Enable i Main Ena...

Страница 53: ...ring the unneeded execution time of user programs to expire and thus increases the cycle Mode 1 Application specific Sum of UP Max Duration for Each Cycle s Sum of the values indicated for Max Duratio...

Страница 54: ...me required to process communication with external partners may however exceed the default value in a CPU cycle For firmware HIMax CPU V4 the value of the maximum duration of configuration connections...

Страница 55: ...ed or during the first cycle of a reload process 5 2 3 2 Hardware System Variables for Setting the Parameters These system variables can be accessed in the SILworX Hardware Editor To this end select t...

Страница 56: ...Run or Reload Deactivation operable with the key switch 1 Assign a global variable to a system variable 2 Assign the same global variable to a digital input 3 Connect a key switch to the digital input...

Страница 57: ...s UDINT System Error Historic Count Counted number of system errors counter resettable UDINT System Warning Count Number of current system warnings UDINT System Warning Historic Count Counted number o...

Страница 58: ...ubordinate enable switches cannot be changed BOOL Enable for non redundant operation ON One single processor module in rack 0 slot 3 may also start with one system bus only Mono Startup Release OFF Bo...

Страница 59: ...ms until the time limit set for global forcing expires DINT CPU Watchdog Time ms Maximum permissible duration of a cycle in ms UDINT Cycle Time last ms Current cycle time in ms UDINT Cycle Time max ms...

Страница 60: ...gram Level Local Forcing Al lowed OFF Forcing not Allowed at Program Level OFF OFF is recom mended ON User program reload is permitted Reload Allowed OFF User program reload is not permitted ON Applic...

Страница 61: ...er program as a raw value Here 1 mA corresponds to a value of 10 000 and the range of values is 0 240 000 As an easier alternative the process value of the REAL data type can be often used instead of...

Страница 62: ...obal variable enter the initial value as safe value 3 Assign the global variable to the integer value of the input The global variable provides the safe value to the user program Perform the following...

Страница 63: ...rt circuits and open circuits refer to the module specific manual 5 2 5 Assignment to Communication Connections Communication connections can be used to send or receive the values of global variables...

Страница 64: ...s from TRUE to FALSE an event is triggered Deacti vated If the global variable value changes from FALSE to TRUE an event is triggered Default value Deactivated Checkbox activated de activated Alarm Te...

Страница 65: ...gering an event Condition H Alarm Value Hysteresis L Alarm Value Hysteresis or H Alarm Value L Alarm Value depending on the global variable type H Alarm Priority Priority of the upper limit default va...

Страница 66: ...current value from a physical input communication or a logic operation If the variable is forced its value does no longer depend on the process but is defined by the user Forcing is used for the foll...

Страница 67: ...restrictions with the consent of the test authority re sponsible for the final system acceptance test 5 3 3 Force Editor SILworX Force Editor lists all variables grouped in global and local variables...

Страница 68: ...pecial tasks that might be executed within a CPU cycle such as reload or synchronization of processor modules Using multitasking the second phase changes so that a CPU cycle runs as follows 1 Process...

Страница 69: ...eds CPU cycle to process an input change registered by the system at the beginning of CPU cycle For this reason the reaction to this input change is only available at the end of CPU cycle The reaction...

Страница 70: ...ltitasking Editor Maximum Number of Cy cles Maximum number of CPU cycle required to process one user program cycle Multitasking Editor Table 23 Parameters Configurable for Multitasking Observe the fol...

Страница 71: ...hardware i HIMA recommends to set the Max Duration for each Cycle s parameter to an appropriate value 0 This ensures that a user program with an excessively long runtime is stopped during the current...

Страница 72: ...on for Each Cycle s has Expired Completion of the First CPU Cycle Completion of the UP 1 Cycle UP 2 Resumes Completion of the UP 2 Cycle UP 3 Resumes The UP 3 Max Duration for Each Cycle s has Expired...

Страница 73: ...Max Duration for Each Cycle s of UP 3 has Expired UP 4 Starts The UP 4 Max Duration for Each Cycle s has Expired Completion of the First CPU Cy cle Completion of the UP 1 Cycle UP 2 Re sumes The Rema...

Страница 74: ...PU cycles of the same duration Multitasking mode 3 allows users to verify if multitasking mode 2 ensures proper program execution even in the worst case scenario Example First CPU Cycle Considered Sec...

Страница 75: ...Requirements for the download Controller in STOP Resource enable switch set to Load Allowed After a download the user program must be launched in SILworX to start safety related operation Use the down...

Страница 76: ...due to the time required by the additional reload tasks To prevent that the watchdog triggers and the controller enters the error stop state both SILworX and the controller verify the additional time...

Страница 77: ...to the controller by performing a reload Changes to the user program parameters Changes to the logic of the program function blocks and functions Changes that allows a reload in accordance with Table...

Страница 78: ...he operating system is delivered with the module HIMA is continuously improving the operating systems The improved versions can be loaded into the module using SILworX 5 6 1 Load Process Update the op...

Страница 79: ...standard IP address The normal operating system now uses the previously configured IP address Restarting after loading the operating system of the module connected to the PADT causes the connection to...

Страница 80: ...to it Characteristics of user groups The name must be unique within the project and must contain 1 31 characters A user group is assigned an authorization type A user group may be assigned an arbitrar...

Страница 81: ...one user with administrator rights 6 2 1 Default User The factory user settings apply if no user accounts were set up for a resource The factory settings also apply after starting a processor module u...

Страница 82: ...and reset modules Start system operation for processor modules Read Write Similar to Read Operator but users may also Create programs Translate programs Load programs into the controller Test program...

Страница 83: ...f the LEDs 7 1 1 Definition of Blinking Frequencies Blinking frequencies of the LEDs Designation Blinking frequencies Blinking1 Long approx 600 ms on long approx 600 ms off Blinking2 Short approx 300...

Страница 84: ...le 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 30 M...

Страница 85: ...cators The rack connection and slot LEDs are labeled Sys Bus LED Color Status Description On Physical and logical connection to the system bus module in another base plate Green Blinking1 Transient di...

Страница 86: ...ive and no configuration data exchange between processor modules Table 35 Maintenance Indicators 7 1 8 Fault Indicators The fault LEDs are labeled Fault LED Color Status Description On System warning...

Страница 87: ...set during the planning phase The Channel LED is lit if the switching point set for HIGH SP HIGH has been exceeded The Channel LED is no longer lit if the switching point set for LOW SP LOW has been...

Страница 88: ...labeled Ethernet LED Color Status Description Blinking x Communication detected on interface Blinking1 IP address conflict detected LEDs adjacent to one another PADT and H F Col blinking PADT Green O...

Страница 89: ...500 X SB 01 400 500 Table 41 Maximum Number of Entries Stored in the Diagnostic History per Module Type i The diagnostic entries can be lost if a power outage occurs just before they could be saved in...

Страница 90: ...0 means not connected Send status Receive status Hexadecimal value 16 0000 F FFF Every two bits represents the state of the inter face with an index Bits 0 and 1 apply to interface 0 and so on Value...

Страница 91: ...in variables 1 024 Number of system bus modules per base plate 1 2 Maximum length of system busses 100 m Using Fiber optic cables see Chapter 3 2 19 6 km and more if system bus la tency is configured...

Страница 92: ...irectly via the field termination assemblies The following section describes the four recommended wiring variants 1 Connection to single connector boards with screw terminals 2 Connection to redundant...

Страница 93: ...Connect the sensors or actuators to a redundant connector board with screw terminals The connector board distributes the signals from one sensor to two redundant modules or merges the signals from tw...

Страница 94: ...ard with cable plug via field termination assembly Connect the individual sensors or actuators to a field termination assembly on a per channel basis Connect two or more redundant sensors or actuators...

Страница 95: ...sensors or actuators to a redundant connector board with cable plug via field termination assembly and system cable The connector board distributes the signal from one sensor to two redundant modules...

Страница 96: ...functional earth in the control cabinet so that it meets the requirements for protective earth All HIMax systems can be operated with earthed L or unearthed Unearthed Operation In unearthed operation...

Страница 97: ...instance do not lay power lines together with 24 V feed lines Earthing the HIMA Controllers While also taking the EMC aspects into account implement the following earthing measures to ensure the safe...

Страница 98: ...take for the potential bounding from the external supply and the I O cables from the field Shielding and earthing of moveable cabinet parts connected to the cabinet frame with earthing straps Standard...

Страница 99: ...sbar 24 VDC Supply Digital Signals Terminals on Field Ter minal Assembly FTA Analog Signals Terminals on Field Ter minal Assemby FTA Terminals Pivoting or Fixed Frame Base Plate Figure 21 Earthing and...

Страница 100: ...Door 16 mm 300 mm Pivoting frame in Figure 22 25 mm 300 mm M 2500 busbar connection with GN YE round ca bles 25 mm 300 mm Table 44 Earthing Connectors The following elements are relevant for the earth...

Страница 101: ...ines and sufficiently distant from electromagnetic active devices electric motors transformers Ensure that the cables to the input modules of the HIMax systems are laid as interference free as possibl...

Страница 102: ...32 01 X AI 32 02 Connector board screw couplings 0 26 2 25 X DI 32 01 X DI 32 04 Connector board screw couplings 0 26 2 25 X DI 32 02 X DI 32 05 Connector board screw couplings 0 26 2 25 X DO 12 01 C...

Страница 103: ...up cables e g red cables for system bus A green cables for system bus B 9 1 5 Mounting a Connector Board Tools and utilities Screwdriver slotted 0 8 x 4 0 mm Matching connector board To install the c...

Страница 104: ...of electronic components causes a corresponding lost heat This depends on the external load of HIMax modules Depending on the structure the device installation and ventilation are thus of importance...

Страница 105: ...or installation type the effective enclosure surface A is determined as follows Enclosure installation type in accordance with VDE 0660 Part 5 Calculation of the enclosure surface A Individual enclosu...

Страница 106: ...approx Temperature State System variable values Temperature State BYTE 40 C Normal 0x00 40 60 C Threshold 1 exceeded 0x01 60 C Threshold 2 exceeded 0x03 Back to 60 C 40 C Threshold 1 exceeded 0x01 Ba...

Страница 107: ...able is connected Check proper polarity voltage and ripple prior to connecting the operating voltage 24 VDC 9 2 2 Starting up the PES Requirements for start up The hardware is installed The hardware i...

Страница 108: ...S on the processor module With a mono system one processor module and at least one system bus module set the mono operation To do so click Set Mono Redundancy Operation on the Online Start up menu Thi...

Страница 109: ...and system bus module 2 Change the rack ID Change the rack ID of one system bus module through the direct connection Also change the rack ID of a second system bus module if existing through the dire...

Страница 110: ...which is farthest from rack 0 to Line Farthest means that connection to this rack passes through most of the other racks or Ethernet segments 3 Perform step 2 for all racks one after the another and s...

Страница 111: ...the controller is in the STOP state Prior to replacing an I O module check if disturbances exist on the external line and if the corresponding sensor or actuator is properly functioning Once a failure...

Страница 112: ...Malfunction of the controller due to insufficient repair Only HIMA is authorized to repair a safety related HIMax system or the modules con tained in it In case of unauthorized intervention in the dev...

Страница 113: ...X CI 24 51 HI 801 188 D Counter input module 24 channels PDF X DI 16 01 HI 801 057 E Digital Input Module 16 Channels SIL 3 PDF X DI 32 01 HI 801 015 E Digital Input Module 32 Channels SIL 3 PDF X DI...

Страница 114: ...otocols and their ap plication PDF Table 49 Overview of the HIMax Documentation 10 2 HIMA Service Training and Hotline Deadlines and the extent of actions for commissioning testing and modifying progr...

Страница 115: ...plates with 10 slots as presented in the examples Small System This redundant system is composed of one base plate and two processor modules The base plate has rack ID 0 Figure 26 Small HIMax System O...

Страница 116: ...01 Page 116 of 122 i HIMA recommends using both system bus modules Distributed Redundancy This system contains four redundant processor modules distributed on base plate 0 and base plate 1 Figure 28...

Страница 117: ...Low Voltage PES Programmable Electronic System PFD Probability of Failure on Demand probability of failure on demand of a safety func tion PFH Probability of Failure per Hour probability of a dangerou...

Страница 118: ...Sequence with Multitasking 69 Figure 13 Multitasking Mode 1 72 Figure 14 Multitasking Mode 2 73 Figure 15 Multitasking Mode 3 74 Figure 16 Wiring 1 Single Connector Board with Screw Terminals 93 Figu...

Страница 119: ...s 54 Table 17 The Hardware System Variables for Setting the Parameters 55 Table 18 Hardware System Variables for Reading the Parameters 59 Table 19 Assigning the Index to Processor Module Slots 59 Tab...

Страница 120: ...ion Displayed in the Online View for the Hardware Editor 90 Table 43 Dimensioning of a HIMax Controller 91 Table 19 Earthing Connectors 100 Table 45 Locked Torque of the Screws for Connecting Wires in...

Страница 121: ...eat dissipation 105 initial value 50 installation 92 licensing protocols 44 lightning protection 101 loading the configuration download 75 reload 75 loading the operating system 78 maintenance 110 max...

Страница 122: ...aul Hildebrandt GmbH Co KG HIMax and SILworX are registered trademark of HIMA Paul Hildebrandt GmbH Co KG Albert Bassermann Str 28 68782 Br hl Germany Phone 49 6202 709 0 Fax 49 6202 709 107 HIMax inf...

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