HIMA HIQuad H41X, System Manual

Page 1: ...Manual HIQuad X System Manual...

Page 2: ...uestions 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 m...

Page 3: ...3 2 Concept for HIQuad H51X 14 3 2 1 The H51X Mono System 15 3 2 2 The H51X Redundancy System 17 3 3 Concept for HIQuad H41X 20 3 3 1 The H41X Mono System 21 3 3 2 The H41X Redundancy System 23 3 4 E...

Page 4: ...Watchdog WD 52 4 7 Modules 53 4 8 F CPU 01 Processor Module 53 4 8 1 Operating System 53 4 8 1 1 General Cycle Sequence 53 4 8 1 2 Operating System States 53 4 8 2 Behavior in the Event of Faults 56 4...

Page 5: ...Configuration Version Parameter 76 6 1 3 6 Rack System Variables 77 6 1 3 7 Locking and Unlocking the Resource 81 6 2 Forcing 82 6 2 1 Time Limits 83 6 2 2 Restricting the Use of Forcing 83 6 2 3 For...

Page 6: ...Systems 100 9 1 11 Cable Colors 100 9 1 12 Connecting the Supply Voltage 100 9 2 Start Up 101 9 2 1 Starting up the Control Cabinet 101 9 2 1 1 Test of All Inputs and Outputs 101 9 2 1 2 Voltage Conne...

Page 7: ...ding manual Lifecycle Phases of a HIQuad X system lifecycle Installation Start up Maintenance and repairs HIQuad X Documentation Overview of the documentation Appendix Glossary Index of tables and ind...

Page 8: ...nk to jump to the corresponding position Safety notices and operating tips are specially marked 1 3 1 Safety Notices Safety notices must be strictly observed to ensure the lowest possible risk The saf...

Page 9: ...0 Page 9 of 110 1 3 2 Operating Tips Additional information is structured as presented in the following example i The text giving additional information is located here Useful tips and tricks appear a...

Page 10: ...tive Maintenance HIMA is responsible for planning and executing preventive maintenance measures Maintenance actions are carried out in accordance with the manufacturer s specifications and are documen...

Page 11: ...Accordance with the Energize to Trip Principle The HIQuad X system can also be used in applications that operate in accordance with the energize to trip principle A system operating in accordance with...

Page 12: ...ctrostatic discharge e g by storing them in their packaging 2 3 Residual Risk No imminent risk results from a HIMA system itself Residual risk may result from Faults related to engineering Faults in t...

Page 13: ...apter 4 9 The I O processing module F IOP 01 uses the I O bus to interconnect the I O modules within one rack The F IOP 01 module safely communicates with the processor modules via one or two system b...

Page 14: ...oint connection The processor module in slot 8 controls and monitors system bus A whereas the processor module in slot 10 controls and monitors system bus B During redundant operation the two processo...

Page 15: ...s results are sent to the I O processing module which writes them to the output modules The output modules thus control the field level e g the actuators During mono operation the signal is forwarded...

Page 16: ...ase rack Figure 3 Example of H51X Mono System The rack IDs do not necessarily have to be arranged as described above but they must be unique To ensure a clearer overview HIMA recommends the following...

Page 17: ...while the system is operating Figure 4 Example of Safe H51X Redundant Operation 1oo2 In contrast to mono operation the entire design of a redundant system is intended to ensure availability Redundant...

Page 18: ...racks can be connected to the system buses in a UP loop DOWN loop or UP and DOWN loop The extension racks are interconnected with system buses A and B via the I O processing module see F IOP 01 manua...

Page 19: ...ck IDs do not necessarily have to be arranged as described above but they must be unique To ensure a clearer overview HIMA recommends the following Arrange the rack IDs in accordance with Figure 5 Bet...

Page 20: ...operation the two processor modules align their data The RJ 45 system bus interfaces on the rear side of the base rack are used to connect the I O modules in the H41X base rack to the processor module...

Page 21: ...ser program s results are sent to the I O processing module which writes them to the output modules The output modules thus control the field level e g the actuators During mono operation the signal i...

Page 22: ...System bus interfaces on the rear side of the base rack Figure 8 Example of H41X Mono System The rack IDs for the HIQuad H41X system are fixed To ensure a clearer overview HIMA recommends the followin...

Page 23: ...n contrast to mono operation the entire design of a redundant system is intended to ensure availability Redundant input modules safely record the values measured by redundant sensors They exchange dat...

Page 24: ...if one system bus is disconnected the system can continue to operate via the redundant system bus If one I O processing module fails the I O modules in the affected rack enter the safe state while th...

Page 25: ...of 16 I O modules to be inserted in slots 1 16 The I O processing module is used to connect the system buses to the I O bus The power distribution modules F 7133 are used to fuse and distribute L and...

Page 26: ...at dissipation of a HIMA standard cabinet achieved by convection i e without additional aids is 300 W This assumes installation of several cabinets next to each other and with their rear side to the w...

Page 27: ...net Total power dissipation Maximum power dissipation per extension rack Fan components 300 W 50 W 3 x K 9203A 300 500 W 50 W 3 x K 9203A K 9202B 500 1000 W 100 W 3 x K 9203A K 9202B Table 3 Fan Compo...

Page 28: ...4 x W x H D 1 8 x H x D Final enclosure free standing A 1 4 x D x W H 1 8 x W x H Final enclosure for wall mounting A 1 4 x H x W D 1 4 x W x D Central enclosure free standing A 1 8 x W H 1 4 x W x D...

Page 29: ...rack H51X Backplane H41X Backplane Extension rack backplane Table 6 Rack Backplanes 4 2 19 Inch Frame The 19 inch frame is the basic mechanical structure of the HIQuad X system The following figure sh...

Page 30: ...figure shows the dimensions of the 19 inch frame a External dimensions 482 6 mm b Mounting space 84 HP 84 x 5 08 mm c Mounting hole distance 465 mm d Mounting depth 263 mm c Mounting hole distance 101...

Page 31: ...02 XG6 Figure 15 Rear View of H51X Backplane 4 2 1 1 Supply of the H51X Base Rack For supply and power distribution HIMA recommends using the following components K 7205 Redundant supply up to a maxim...

Page 32: ...Power Supply for Extension Racks The 5 V power supply for extension racks is connected to the following terminals Spring terminal Cross section and color XG2 1 XG2 13 Vcc 2 5 mm YE XG3 1 XG3 13 Vcc 2...

Page 33: ...12 slot 1 slot 12 XG3 LS slot 1 slot 12 XG4 LS reference potential for auxiliary voltage 24 VDC XG8 Figure 16 Rear View of H41X Backplane 4 2 2 1 Supply of the H41X Base Rack For supply and power dist...

Page 34: ...use XG9 1 2 L1 L2 2 5 mm RD Maximum 16 A gL XG 10 1 2 L 2 5 mm BK Table 11 Connection to the 24 V Power Supply 4 2 2 2 5 V Power Supply for Extension Racks The 5 V power supply for the extension rack...

Page 35: ...V Auxiliary Voltages in I O Modules The connection to the 24 V power supply of the cable plugs is performed as shown in Figure 17 The Faston flat connectors XG3 and XG4 are supplied via field termina...

Page 36: ...free use XG6 Do not use it for HIQuad X L 24 VDC XG 11 Do not use it for HIQuad X GND 5 VDC XG 12 Potential distributor for free use XG13 Potential distributor for free use XG14 Figure 18 Rear View of...

Page 37: ...rature threshold Temperature state Temperature State X BYTE 40 C Normal 0x00 40 C Warning Threshold 1 exceeded 0x01 60 C Error Threshold 2 exceeded 0x03 Table 14 Thresholds of the Temperature States I...

Page 38: ...r supply units see Figure 19 Redundant with redundant power supply units see Figure 20 HIMA uses red cables for positive potentials L and black cables for negative potentials L Decoupled SELV PELV pow...

Page 39: ...HIMA power supply units of the PS 1000 series are designed and suitable for a mean time to failure MTTF of 30 years Power supply units from other manufacturers must be checked to ensure that they mee...

Page 40: ...aximum current input in each base rack to 16 A Users must implement external measures to ensure that the power supply does not fall below 0 8 x UN 19 2 VDC If no redundant power supply is available th...

Page 41: ...e 19 Connection to one or redundant power supply units see Figure 19 Connection to 24 VDC for the I O processing modules from the same source as the H51X base rack Redundant supply of the F 7133 power...

Page 42: ...ower supply units and for the I O level at the connection for mono components see Figure 20 Connection to redundant power supply units see Figure 20 Attach to the connector for mono components see Fig...

Page 43: ...the extension racks with odd rack IDs while a redundant power supply unit L2 powers the racks with even IDs In this example the redundancy of the I O level is portioned based on the rack IDs so that...

Page 44: ...The buffer module in slot 7 compensates for voltage dropouts of the expansion racks with even rack IDs In doing so redundant I O levels can be assembled based on the rack IDs If one buffer module fail...

Page 45: ...ee Figure 19 Inline terminals XG5 1 XG5 13 to 24 V power supply XG5 13 for connecting to the I O processing modules Connection to one or redundant power supply units see Figure 19 Connection to 24 VDC...

Page 46: ...g module in the extension rack terminals XG 3 L see Figure 20 The power supply units must be able to bridge voltage dropouts of up to 20 ms Inline terminals XG5 1 XG5 13 to 24 V power supply XG5 13 fo...

Page 47: ...O modules is as follows F 7133 power distribution module Supplies the I O modules in Slot 18 Slot 1 4 Slot 19 Slot 5 8 Slot 20 Slot 9 12 Slot 21 Slot 13 16 Table 15 Assignment of F 7133 Power Distrib...

Page 48: ...d XG5 for GND The supply voltage is distributed in a star configuration see Figure 25 The resistance of a 5 V supply line with a maximum length between H51X base rack and extension rack of 12 m must b...

Page 49: ...oduct Description HI 803 211 E Rev 1 01 00 Page 49 of 110 GND connectors XG4 and XG5 on the rack rear side 5 VDC connectors XG2 and XG3 on the rack rear side Figure 28 Extension Rack Connected to a 5...

Page 50: ...stem is distributed among two control cabinets the 5 V power supply must be provided in the control cabinet without base rack by a separate power supply unit see Chapter 4 3 8 for details The wires on...

Page 51: ...ration communication runs on both system buses simultaneously If only one processor module is inserted in the base rack the system runs in mono operation with only one system bus Redundant operation e...

Page 52: ...um System Bus Latency s is set to System Defaults the maximum system bus latency is determined by the system For the 100 s setting the maximum system bus latency is set to this value For system bus co...

Page 53: ...s Controlling the cyclic run of the user programs Performing the self tests of the module Controlling safety related communication via safeethernet Managing the processor modules redundancy synchroniz...

Page 54: ...No valid configuration is available in the memory Loading with error STOP LOADING OS Processor module stopped The operating system is loaded in the non volatile memory Loading the operating system us...

Page 55: ...ATION Processor module stopped No valid configuration is available in the memory Loading with error STOP LOADING OS Processor module stopped The operating system is loaded in the non volatile memory L...

Page 56: ...g a PADT command to stop STOP state Table 19 Operating System States User Interventions i The cycle time increases by the number of modules used in the system This applies irrespective of whether or n...

Page 57: ...ng module The module s tasks include exchanging data with the processor modules and providing the watchdog signal to the output modules via system bus A and system bus B 4 10 F COM 01 Communication Mo...

Page 58: ...5 Z 7035 3335 4 3 DO Ex i HI 803 187 E F 3349 Z 7150 3349 8 3 DO 0 5 A HI 803 188 E F 3422 Z 7139 3422 8 Relay 60 VDC HI 803 189 E F 3430 Z 7149 3430 4 3 Relay 110 VDC HI 803 190 E F 5220 Z 7152 5220...

Page 59: ...t for up to one cycle before it is detected while reading in the values the minimum noise blanking time can be determined by subtracting a cycle from the maximum noise blanking time value Minimum nois...

Page 60: ...on 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 noise blanking can be per...

Page 61: ...cides if noise blanking can be performed at this point in time based on the following rule Safety time elapsed time 2 x watchdog time 0 Noise blanking is possible in the 1st and 2nd cycle since the in...

Page 62: ...es the transient interference on the input module and on the buses system bus and I O bus Noise blanking on the input module can be deactivated in the properties SILworX default Activated see the inpu...

Page 63: ...opped Afterwards the user program cannot be started without a valid software activation code for the protocols used in the project invalid configuration 4 14 Connecting the PADT to the System The phys...

Page 64: ...he corresponding page for more details To activate a function with an activation code 1 Generate the software activation code on the HIMA website www hima com en using the system ID of the controller...

Page 65: ...y related operation is still ensured even if one of the two redundant processor modules fails 5 1 2 Increasing Redundancy If a new processor module is added to a running HIQuad X system it automatical...

Page 66: ...assigned to a channel channel number to both channels of the redundant modules Refer to the Hardware Editor section of the SILworX online help for more details 5 3 System Bus Redundancy The HIQuad X s...

Page 67: ...t affect the user program Local and global variables exist Local variables are valid in a delimited project area in a user program or function block Global variables can be used in several function bl...

Page 68: ...permissible variable types in connection with the structure tree nodes Type Project Configuration Resource Program type Function block type Function type VAR X VAR_EXTERNAL X VAR_GLOBAL X X X 1 VAR_I...

Page 69: ...rameters are defined at different project levels The system variables and parameters are configured in SILworX either in the Properties dialog box of the corresponding structure tree node or in the de...

Page 70: ...ycle time see Target Cycle Time Mode Range of values 0 7500 ms Default value 0 ms can be changed online The maximum target cycle time value may not exceed the configured Watchdog Time ms minus the min...

Page 71: ...cense is required for setting the maximum system bus latency to a value System Defaults Application specific Allow Online Settings Y TRUE All the switches parameters listed under FALSE can be changed...

Page 72: ...ult setting is TRUE Application specific FALSE Global forcing is not permitted for this resource Global Force Timeout Reaction N Specifies how the resource should behave when the global force timeout...

Page 73: ...is the number of changed user programs The default setting is Fixed tolerant i After the first reload activation cycle the values of watchdog time target cycle time and target cycle time mode apply i...

Page 74: ...the Max Com Time Slice ms system parameter located in the properties of the resource For each F COM module 3 ms For each redundant safeethernet connection 1 ms For each non redundant safeethernet con...

Page 75: ...Config System parameter Max Duration of Configuration Connections ms nCOM Number of modules with Ethernet interfaces CPU COM nRIO Number of configured remote I Os nPADT Maximum number of PADT connecti...

Page 76: ...compatible with the operating systems of the modules The value of Minimum Code Generation only needs to be increased for converted projects if additional functions of a controller should be used If fe...

Page 77: ...cific 1 The operating system handles the system parameter in a safety related manner yes Y or no N Table 26 System Parameters for Output Variables Input Variables Variables that are not selected in th...

Page 78: ...milliseconds and seconds since 1970 01 01 0 999 ms 0 4 294 967 295 s UDINT Last Communication Warning ms Last Communication Warning s N Date and time of the last communication warning in milliseconds...

Page 79: ...L Read Only in RUN Y TRUE The following operator functions are locked Stop Start Download FALSE The following operator functions are unlocked Stop Start Download BOOL Redundancy Info Y Bit coded redun...

Page 80: ...TE Remaining Global Force Duration ms Y Time in ms until the time limit set for global forcing expires DINT Watchdog Time ms Y Maximum permissible duration of a RUN cycle in ms dependent on the contro...

Page 81: ...ibes a simple case in which a key operated switch is used to lock or unlock all interventions to the resource Example To make a controller lockable 1 Define a global variable of type BOOL and set its...

Page 82: ...ible for the acceptance test Only remove existing forcing restrictions with the consent of the test authority responsible for the acceptance test When forcing values the person in charge must take fur...

Page 83: ...tely using a key switch To do so the Force Deactivation system variable must be linked to a digital input connected to a key switch WARNING Failure of safety related operation possible due to forced v...

Page 84: ...rogram and forcing 6 2 5 Forcing and Scalar Events When forcing a global variable used to create scalar events observe the following points The events are created in accordance with the force value Th...

Page 85: ...ete change user accounts user groups and the user management and define the default user account They may also perform all SILworX functions Read and Write Allows users to perform SILworX functions ex...

Page 86: ...operating voltage The user accounts of a controller also apply to the connected remote I Os Users log in to a controller using the user group name and password If they use the user group name belongin...

Page 87: ...modules Reset cycle time and fault statistics Set the system time restart and reset the modules Start system operation for processor modules Forcing Read Write Similar to Read Operator but users may a...

Page 88: ...oup Always define a password for the PES user account with Administrator access mode i Generally passwords are to be used Suitable passwords are composed of more than 10 characters and contain numbers...

Page 89: ...s Blinking1 see the following tables The indication of errors or faults has priority over the indication of warnings Warnings cannot be reported if errors or faults are being signaled 7 2 Diagnostic H...

Page 90: ...ype MMMM status Mod mm OUT AAAA IN EEEE channel OUT aaaa IN eeee The following table describes the data fields in the message Data field Format Description S Decimal Slot number of the I O module MMMM...

Page 91: ...Module Type Text Permissible module types Type of module which is plugged into the rack Configured Module Type Text Permissible module types Type of module which is configured and loaded in the contro...

Page 92: ...s A Value Description 0 The interface is OK 1 The interface detected an error during last reception now it is OK 2 An error occurred on the interface 3 The interface is switched off Connection Status...

Page 93: ...ply Input Voltage 24 VDC 15 20 rp 5 SELV PELV Table 34 Environmental Conditions 8 2 Dimensioning For details refer to the component specific manuals and communication manual HI 801 101 E For each reso...

Page 94: ...the conditions of use specified in Chapter 2 1 Observe the instructions for installing base racks and other components specified in the corresponding manuals 9 1 2 Connecting the Field Level The fiel...

Page 95: ...ogether with field lines or 24 VDC supply lines For further information see Chapter 9 1 3 2 Observe the instructions provided in this manual related to grounding shielding and cable routing to sensors...

Page 96: ...face of the pivoting frame 1 ensuring safe electrical contact Stainless steel screws and flat washers are used to prevent electrical corrosion 2 The components of the cabinet frame 3 are welded togeth...

Page 97: ...mm2 grounding straps 5 The busbars can also be used as a separate potential e g to connect to the field cable shielding if the grounding straps between the busbars and the control cabinet are removed...

Page 98: ...VDC supply Filter surge protective device Digital signals Analog signals Inline terminals Pivoting or fixed frame Extension rack Base rack Cabinet frame Cage nuts and cage clamps 25 mm grounding conne...

Page 99: ...d faults occur faulty control signals can be triggered For this reason HIMA recommends using ground fault monitoring for ungrounded operation Some application standards e g DIN EN 50156 1 2005 prescri...

Page 100: ...o avoid compensation currents Additionally the requirements specified in the module specific manuals must be observed 9 1 10 Lightning Protection for Data Lines in HIMA Communication Systems Lightning...

Page 101: ...on of ground fault measuring facility which may be connected to the system A megohmmeter or a special measuring instrument must be used to check each connection against ground 9 2 1 2 Voltage Connecti...

Page 102: ...t If the system is only equipped with one processor module mono system set mono operation To do so click Set Mono Redundancy Operation in the Online Start up menu This setting only takes effect if a m...

Page 103: ...g to the power supply the HIQuad X system modules start in random order This applies to the HIQuad X modules as well as to the connected remote I Os 9 3 2 Connecting the Redundant Power Supply Because...

Page 104: ...rst steps manual HI 801 103 E Introduction for engineering HIMA controllers using SILworX PDF SILworX online help CHM Communication manual HI 801 101 E Communication protocols and their application PD...

Page 105: ...ty related module has no influence on the safety related modules MAC Address Media access control address hardware address of one network connection PADT Programming and debugging tool in accordance w...

Page 106: ...H41X 35 Figure 18 Rear View of Extension Rack Backplane 36 Figure 19 Mono 24 V Power Supply 38 Figure 20 Redundant 24 V Power Supply 39 Figure 21 Mono Connection to H51X Base Rack 24 VDC 41 Figure 22...

Page 107: ...Power Supply Units 51 Table 17 Allowed Power Consumption in Relation to the Number of Power Supply Units 51 Table 18 Operating System States States Entered 55 Table 19 Operating System States User In...

Page 108: ...Diagnostic message I O module 89 Diagnostics 88 History 88 Energize to trip principle 11 ESD protection 12 Loading the operating system 102 PADT user management 84 PES user management 85 Programming 6...

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Page 110: ...t notice 2017 by HIMA Paul Hildebrandt GmbH Specifications subject to change without notice MANUAL System HI 803 211 E For further information please contact HIMA Paul Hildebrandt GmbH Albert Basserma...