Planar4 System Catalog

Electronic Systems
Planar4
System Manual
HIMA Paul Hildebrandt GmbH + Co KG

Industrie-Automatisierung
Attention:
Maintenance on supply, signal and data lines may only be executed by qualified personnel with
consideration off all ESD protection measures. With direct contact of this lines the maintenance per-
sonnel have to be electrostatic discharged!
Important Note
All HIMA products mentioned in this manual are protected with the HIMA trade-mark. As not diffe-
rently noted down this is possibly also valid for other mentioned manufactueres and their products.
The technology is subject to changes without notice.
All technical statements and data in this manual have been worked out very carefully, and effective
checks and inspections have been applied. This manual may however contain flaws or typesetting
errors. Therefore HIMA does not offer any warranties nor assume legal reponsibility nor any liability
for the possible consequences of any errors in this manual. HIMA would appreciate being informed
on possible errors.
Conditions of Supply and Delivery
The „General Conditions of Supply and Delivery for the Products and Services of the German Elec-
trical Industry“ apply for our deliveries and services.
Eventual complaints can be recognized only when we are being notified within 14 days after receipt
of the merchandize.
The prices shown in a special list are valid ex works, packing charges excluded. The prices ars sub-
ject to change.
Inhaltsverzeichnis
Table of Contents
1 The HIMA Planar4 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Safety-Related Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Diagnosis and Error Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Communication with other Sytems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Functions of the Modules in the
HIMA Planar4 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Relay Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Logic Function Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Time Delay Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Analogue Limit Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7 Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.8 Modules for Power Supply,
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.9 Intrinsically Safe Circuits and Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.10 Current Circuits with Safe Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Operating Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Voltage Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Wiring of the Subracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Definition of Signals and Standard Load Factors . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Short-Circuit Strength of the Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.8 Current Consumption of Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Mechanical Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Modules of the HIMA Planar4 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Subracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Cabinets and Racks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5 Wiring and Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 Colours of Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Wire Cross-Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4 Connecting the Field Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 Tests within the Quality Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Final Product Testing of Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Factory Testing of HIMA Control Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.1 Mechanical Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.2 Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.3 System Test at Increased Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7 Engineering Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8 Start-Up, Maintenance, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1.1 Testing the Inputs and Outputs for External Voltage
I
Inhaltsverzeichnis
and Earth Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.1.2 Connection of Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.1.3 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.3 Electrostatic Discharge (ESD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.4 Repair of Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.5 Supply of Internal Documentation of the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.6 Service and System Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9 Safety Controls with the Planar4 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.1 Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.2 Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.3 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.3.1 Safety Standards and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.3.2 Module Test according to DIN V 19250. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.3.3 Module Test according to IEC 61508 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.4 Functional Principles of Safety-Related Modules . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.4.1 Module Safety by Fail-Safe Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.4.2 Module Safety by Comparison Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.5 Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.5.1 Closed-Circuit Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.5.2 Latching Circuits (Memory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.5.3 Negation (Blocking Element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.5.4 Input Circuits for Inductive Sensors (proximity switches) . . . . . . . . . . . . . . . . . . . . 38
9.5.5 Coupling to Safety-Related Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10 Certification of the Planar4 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.1 Basis of the Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.2 Report to the Certicicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.3 Notes to the Electrical Equipment of Furnace Controls
according to DIN VDE 0116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.1 Communication via MODBUS Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.1.1 Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11.1.2 Reading of Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11.1.3 Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.1.4 Reading of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.1.5 Events Checks via Standard Codes 1, 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.1.6 Time Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.2 Communication via Profibus-DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.3 Communication via Ethernet (OPC Server). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12 Summary of the Symbols used in the Data Sheets . . . . . . . . . . . . . . . . . . . . . . 50
II
The HIMA Planar4 System
1 The HIMA Planar4 System

The increasing complexity and the capacity of the processes in today’s
process engineering industry require more and more half or fully automa-
tic controls. While the observation of safety regulations is predominant in
process engineering, high availability is extremely important in production
processes with big capacities.
The awareness of environmental issues of today, the safety orientation as

well as the legal regulations greatly influence the planning of modern in-
dustrial plants. Here, plant failures should have little or no consequences
at all for people or for the plant itself.
The possible hazard of big industrial plants or in traffic technology lies in

the system as a whole. It must be monitored and be put to a clearly defi-
ned, undangerous state with the help of controls. For this reason the
functional failure of the control may result in a critical reaction.
The HIMA Planar4 System represents a modular electronic circuit system

featuring Euro modules for designing hard-wired safety-related control
and monitoring systems. It is operated with only one system voltage of
24VDC. Practice-oriented design and uncomplicated project planning en-
able an easy installation. All modules are equipped with a self-diagnosis
for fault detection; additional communication modules enable the data
transfer from the control to other systems.
The HIMA Planar4 System was developped on the basis of decades of ex-
perience in the technology of hard-wired programmed controllers; it is ba-
sed on the approved and sucessfull Planar System F. The high quality
standard of HIMA modules is achieved by the use of high quality compon-
ents, carefully proportioned circuits, sophisticated modern manufacturing
technology and thorough and automatic testing procedures.
1.1 Safety-Related Modules

A safe control must be designed in a way that each failure of components
and other imaginable influences do not cause impermissible failure states.
Safety-related systems are required e. g. for trains, lifts, presses, eleva-
tors, incinerator plants etc.
The safe state is the state into which a system can be put from its current
operational state and which has a system specific lower hazard potential
than the operational state. The absolutely safe state for systems with a
safety state is according to DIN 31000 the state with the lowest amount of
energy involved.
In the common electronic control modules DC voltage signals are proces-

sed (static circuits). This simple design cannot be used for safety related
modules, as the failure direction of electronic components cannot be defi-
ned, and for this reason in case of a failure the deenergized state cannot
be guaranteed.
1
The HIMA Planar4 System comprises special TÜV tested modules which
meet the requirements for safety-related control systems. The safety-rela-
ted electronic modules use the dynamic principle: the input and output si-
gnals are still static DC voltage signals, but the internal processing of
these signals is made dynamically. For this purpose each safety-related
module has its own integrated function frequency generator.
Fig. 1 shows the principle structure of a safety-related AND element as an

example. The V1 transistor can only amplify the rectangular signal of the
function frequency generator if the E1 contact is closed. The same prin-
ciple of function is true for the V2 transistor with contact E2. Thus the out-
put stage is controlled, and at the secondary side of the transformer an AC
voltage is generated which is available at output A after rectification as 1-
signal.
Fig. 1: AND function in safety-related design
With a failure of each component in the safety circuit the output is deener-
gized. The safety function is not endangered when up to three errors occur
within the circuitry. All requirements concerning the fail-safe shutdown are
met by use of the dynamic principle.
The safety related modules of the system are tested according to DIN V
19250 and IEC 61508. All modules without microprocessors are usable in
the requirement classes 1...7, corresponding to SIL 4 according to IEC
61508. Modules with microprocessors can be used up to requirement
class 6 (corresponding to SIL 3). The modules are signed in the data sheet
with the symbol .
1.2 Diagnosis and Error Indication

Failures or malfunctions in a control require an extensive error detection
by skilled personnel with knowledge and documentation of the system.
The resulting shutdown periods of a plant can cause the owner of a plant
a lot of expense. With the intention to shorten these times of a shutdown
to a minimum the entire Planar4 System is equipped with a self-diagnosis.
2
A diagnosis and communication subassembly (DCM) integrated on each

module samples all input and output signals, reproduces the functions of
the module and compares them with the really existing functions. So dis-
crepancies of the signals can be detected immediately; the DCM activates
an electronic output ERR (suitable for busbar wiring), and a relay (with
floating contact suitable for loop wiring) is deenergized. At the same time
a red light emitting diode ERR on the front plate indicates unambiguously
the position of the faulty module. Fig. 2 shows the function principle. For
the reasons of clarity the input and output signals of the DCM are depicted
as bus conductors; practically there are non-interacting single connections
used.
Fig. 2: Diagnosis and communication subassembly
If an error occurs only from time to time, the fault signal remains stored on
the module. This arises also if the DCM generates a fault signal caused by
external manipulations (e. g. a short-circuit at an output). The fault signal
can be reset only by switching off the supply voltage for a short time (e. g.
by pulling out and inserting the module again).
At input modules with line monitoring the external lines are checked for
wire break and short circuit. A line fault is not indicated via ERR but it is
announced via separated signal outputs and displayed by LEDs on the
front plate. In the same way fuses in output circuits are monitored and in-
dicated in case of a fuse tripped.
A green light emitting diode RDY (Ready) signalizes that the connected
operating voltage (24 V DC) has a level of at least 20 V.
Thus in case of an error the faulty module can be localized very quickly;
faulty modules can be replaced during operation. So the periods of plant
shutdowns caused by a faulty control system can be reduced to a mini-
mum.To avoid shutdown periods completely, i. e. for highest availability, a
redundant design of the control is recommended. Then the plant can be
operated in a single channel mode if one module fails, and a new start-up
of the production after fault locating is not necessary. The self-diagnosis
and the display of the faulty module replaces the additional equivalence
monitoring of both channels which was necessary till now for systems with
redundant design.
3
1.3 Communication with other Sytems

The diagnosis and communication subassembly DCM on the modules of
the HIMA Planar4 System enables the communication between a hard-
wired control and other systems , e. g. a process control system. For this
function each Planar4 subrack designed for communication is equipped
with a communication module at module location 21 which is connected to
a bus system and transfers the data of the modules at the module locati-
ons 1...20.
Each subrack requires a separate communication module.
The following information can be read out from the modules:
– general information like type and state of the inserted module, errors
in input and output circuits, voltage supply,
– signal states of all inputs and outputs,
– events (binary signal changes of the inputs and outputs with time),
– residual delay of time delay elements,actual values and limit values of

limit monitors.
The communication with other systems has a three-level structure:
– communication internally on each module with the diagnosis and com-

munication subassembly (DCM), conditioning of the module data,
– communication within the subrack between the modules and the com-
munication module via the bus PCB (cyclic scanning of all modules by
the communication module),
– communication externally between the communication module and

other systems via a bus.
The external data transfer from a Planar4 System to other systems is pos-
sible via an RS 485 interface (MODBUS or Profibus-DP) or Ethernet
10BaseT (OPC server with protocol TCP/IP). Depending on the type of
data transfer different types of communication modules are used.
A detailed description of the communication to other systems can be found

in the chapter “Communication” in this system manual.
4
Functions of the Modules
2 Functions of the Modules in the

HIMA Planar4 System
The type designation of the modules consists of five digits. It is defined ac-
cording to the following code:
Digit Allocation
1 2 3 4 5
1 Input modules
2 Output modules
3 Relay modules
4 Logic function modules
5 Time function modules
6 Analogue modules
7
8 Communication module
9 Power supply, accessories
0 no certification
1 (Ex) certificate
2 TÜV certificate, safety-related
3 (Ex) and TÜV certificate
4
0..9 0..9 Counting numbers 00...99
0 Standard design
1..9 Modification
2.1 Input Modules

Module Inputs Output
Type Functions Proximity switch Contact (Ex)i Line monitoring 1-signal RC / SIL
12 100 4 • • • • 7/4
13 110 2 • • • • • 7/4
If mechanical contacts are used for input modules instead of proximity

switches, they must be equipped in the field with rtesistors. For this appli-
cation the details in the data sheet must be regarded.
Notes for the (Ex) use of modules are mentioned in the chapter “Modules
for Intrinsically Safe Circuits”.
2.2 Output Modules

Type Functions 1-signal with pre-logic Switch Fuse with monitoring Power RC/SIL
22 100 4 • • 25V/3W 7/4
22 120 1 • • • • 25V/24W 7/4
22 121 1 • • • • 60V/24W 7/4
5
2.3 Relay Modules

Type Functions 1-signal with Fuse Fuse with Switching voltage RC / SIL
pre-logic monitoring
32 100 2 • • • 24 V =, 24 V ~ 7/4
32 101 2 • • • 48/60 V =, 60 V ~ 7/4
32 102 2 • • • 110 V =, 127 V ~ 7/4
32 103 2 • • • 220 V =, 230 V ~ 7/4
32 110 4 • • • ≤ 250V = / ~ 4/2
2.4 Logic Function Modules

Module
Type Functions Logic function RC / SIL
42 100 4 AND element with 5 inputs, 1 with OR 7/4
42 110 8 AND element with 2 inputs 7/4
42 200 7 Element combination AND/OR/blocking element 7/4
42 300 8 OR element with 2 inputs 7/4
42 400 4 Blocking element, direct and inverted output 7/4
42 500 4 Selection element, 2oo3 voting 7/4
2.5 Time Delay Modules

Module
Type Functions RC / SIL
52 100 1 Time delay element 6/3
52 110 4 Time delay element SEVA up to 15 s 5/3
2.6 Analogue Limit Monitor

Module
Type Functions Description RC / SIL
62 100 2 Analogue limit monitor 0/4...20 mA 6/3
2.7 Communication Modules

Module
Type Functions Description RC / SIL
80 100 1 Communication module for MODBUS, non-interacting -
80 101 1 Communication module for Profibus-DP, non-interacting
80 102 1 Communication module for Ethernet (OPC server), non-interacting
6
2.8 Modules for Power Supply,

Accessories
Module
Type Functions Description AK / SIL
90 100 4 Fuse module 24 V DC with monitoring -
90 300 2 Bypass module, non-interacting -
90 900 - Subrack, soldering connection -
90 901 - Subrack (Ex)i, soldering connection -
90 902 - Subrack, termipoint/wire-wrap -
90 903 - Subrack (Ex)i, termipoint/wire-wrap -
2.9 Intrinsically Safe Circuits and Modules

Different types of protection according to EN50014 (DIN VDE 0170/0171,
part 1) are applied to electrical installations in order to prevent the risk of
explosion within explosive atmosphere.
In the Planar4 System two variants are applicated:

– Modules for control of (Ex)d valves,
– Modules with (Ex)i circuits
These installations are called “corresponding electric installations”.
For use of the (Ex)d installations the related modules must be equipped
with fuses only with the values mentioned in the Test Certificate.
The circuits of the type of protection “intrinsically safe”, designation “i” ac-
cording to EN 50020 (DIN VDE 0170/ 171, part 7), limit the currents and
voltages prevailing in the sensor circuits in a way to prevent sparks and
thermal effects during operation or in the case of malfunction (under fixed
testing conditions), which otherwise could cause explosions within explo-
sive atmospheres.
Intrinsically safe amplifiers are used for transmitting control commands

from intrinsically safe circuits to circuits that are not intrinsically safe and
vice versa. Due to the design of these modules all intrinsically safe circuits
within the modules are reliably protected against the impact of external
voltages by not intrinsically safe circuits and the intrinsically safe circuits
are electrically isolated from the supply voltage and the output circuits up
to 250 V.
The intrinsically safe parts of corresponding electric installations are divi-

ded into the categories “ia” and “ib”. Moreover, the parts are divided into
group I (mines susceptable to firedamp) and group II (hazardous areas ex-
cept mines susceptable to firedamp). An indication of temperatures
(T1...T6) does not apply as here it concerns corresponding electrical in-
stallations which must be installed outside the hazardous areas.
7
Example of a designation for the control circuit of a corresponding electri-

cal installation:
II(1)G [EEx ia] IIC (according to european guidelines)
II Operation range: device group

1G Operation range: device category
[ ] Designation of a corresponding electrical installation
EEx Installation with type of protection according to EN
ia Type of protection “intrinsically safe”, category ia
IIC Temperature class (test gas mixture,
21 ± 2 % of hydrogen in air
Modules with intrinsically safe circuits have an EC Prototype Test Certifi-

cate. These certificates are part of the concerning data sheets of this sy-
stem manual.
The number of the certificate contains statements as shown in the follo-

wing examples:
PTB 97 ATEX 2164 X (according to european guidelines)
PTB Testing authority

97 Year of issue
ATEX Type examination according to EC guideline 94/9/EG
2 Sign of test department
164 Consecutive number
X Specific conditions
The indication of specific conditions (X) are e. g. notes on:

– arrangement of the module outside hazardousareas,
– mounting with type of protection IP20 according to DIN 40050 (protec-
tion against medium-sized foreign bodies, no protection against
water),
– interconnection of intrinsically safe circuits (The statements in the cer-
tificate for parallel connection do not indicate that the correct function
of the modules is guaranteed even when connected in parallel),
– features of the wiring.
Modules for intrinsically safe circuits are signed in the data sheets with the
symbol .
When fitting HIMA modules with intrinsically safe circuits into subracks
and cabinets, the following items should be observed (cf. also EN 50014,
EN 50020, DIN VDE 0165):
• Use of female connectors with higher resistance to creepage and
coding pins
• Separation of intrinsically safe and non-intrinsically safe terminals,
distance of ≥ 50 mm or partition (filament dimension ≥ 50 mm)
• Intrinsically safe lines and cables with insulation in light-blue colour
• Separation of intrinsically safe and non-intrinsically safe lines and
cables or additional insulation
• Use of wiring protective coversor pins of the female connectors
covered with shrink sleeves
8
• Use of power supplies with safe isolation

• limitation of the output voltage of the power supplies to ≤ 30V
• Protection against system interference by disturbing voltages
For modules with intrinsically safe circuits coding pins must be used on the
female connector (on pin d6) in the subrack in order to ensure that the in-
trinsically safe circuits are not endangered by inserting non-intrinsically
safe modules into slots with intrinsically safe functions. The module loca-
tion must be designated with the type of the module.
2.10 Current Circuits with Safe Isolation

Safe isolation means preventing the transfer of the voltage of one circuit
into another one with sufficient safety.
The safe isolation is achieved by the use of optocouplers (DIN VDE 0884),
isolating transformers or/and relays.
For the protection against dangerous electric shocks the chemical industry
recommends a low functional voltage with safe isolation according to DIN
VDE 0100 part 410 (NAMUR recommendation NE 23). Through this pro-
tection measure it is intended to achieve that undangerous work like
maintenance or repair can be carried out with the plant running. This grea-
tly increases the availability of the plant.
Relay amplifiers effect a safe isolation of the inputs and the supply voltage
from the output contacts; buffer amplifiers effect a safe isolation of the in-
puts from the outputs as well as the supply voltage, each in accordance to
DIN VDE 0106 part 101/11.86. The clearance in air and the creepage di-
stance are dimensioned for overvoltage class II resp. III up to 300 V. Ac-
cording to DIN VDE 0160 the overvoltage classes are defined as:
– Overvoltage class III

circuits which are designed for the connection to the mains supply
– overvoltage class II
circuts which are not designed for the connection to the mains supply
The overvoltage classes and the notes of safe isolation are indicated in the
data sheets of the concerning modules.
To prevent electric shocks at output circuits with high switching voltage re-
lay amplifiers should be placed in separate subracks. Additionally the rear
part of these subracks must be covered with a barrier; optionally the con-
nector pins may be covered with shrink sleeves.
9
For your notes
10
System Data
3 System Data
3.1 Operating Voltage
The HIMA Planar4 System operates on one voltage only. The operating
voltage required for the modules is defined according to DIN 19240 (7.85)
as follows:
Nominal voltage 24 V DC, -15...+20 %,

20.4 V...28.8 V
Maximum admissible 18.5 V...30.2 V
tolerance for continuous (including ripple)
operation
Maximum peak value 35 V for 0.1 s
Admissible ripple r < 5 % effective value,
rpp < 15 % peak to peak value
Reference potential L- (negative pole)
Grounding of the reference pole
is admissible
The modules are overvoltage-protected. This protection serves also as
polarity safeguard. The connected operating voltage is signalized on the
front plate of the modules by a green light emitting diode RDY (Ready) if
it has a level of ≥ 20 V.
In order to ensure the correct function of the control, the operating voltage
24 V DC must be monitored by means of a voltage measuring device. If
the voltage goes down to a value of ≤ 18 V, the supply voltage of the con-
trol or at least of the output modules must be cut off.
3.2 Voltage Supply

In the range of voltage supply for HIMA systems there are used three dif-
ferent terms:
L+ positive pole (power voltage)

EL+ positive pole (control voltage)
L- negative pole (reference pole)
For L+ and EL+ the same definitions as mentioned at item 3.1are valid.
Due to the admissible ripple for control voltage (EL+) and power voltage
(L+), for a connection to single-phase mains supply there are power sup-
ply units with bridge rectification and smoothing required or stabilized po-
wer supply units. The HIMA standard power supply units (stabilized types)
meet these requirements; additionally they are able to compensate dips of
the primary supply voltage up to 20 ms under full load. Detailed informati-
on is available from the HIMA brochure “Power Supply and Current Distri-
bution”.
Note: To reduce the total power loss in principle the use of stabilized (swit-
ched-mode) power supply units is recommended.
11
System Data
The EL+ is defined to be a voltage which is able to compensate voltage

dips up to 20 ms per second (according to NAMUR NE 21). This require-
ment can also be met by the L+ supply, e. g. when HIMA standard power
supply units are used or by application of a battery back-up.
High current peaks (e. g. caused by lamps, 7...10-fold nominal current)

must be compensated by power supply units sufficiently dimensioned or
by back-up batteries. If this is not provided then for supplying the electro-
nic modules a decoupled supply voltage EL+ is required.
The decoupling is also necessary when using power supply units for con-
nection to three-phase current. Due to their three-phase bridge rectificati-
on they do have a sufficiently low ripple but no compensation of voltage
dips.
A decoupling consists of a power diode and a capacitor (approx.
7000...10000 mF per 1 A current load). It buffers the control voltage, and
the diode prevents a feedback onto the power voltage. Detailed informati-
on about decouplings is available from the brochure “Power Supply and
Current Distribution”.
Fig. 3: Principle of supply with decoupling
The decoupling of the control voltage from the power voltage can be
achieved also by the use of two separate power supply units.
An operation without decoupling is only possible if the user provides an
uninterupted 24 V DC supply voltage according to NAMUR NE 21.
If a redundant power supply is required, the supply units connected in par-
allel must be decoupled via additional diodes. These diodes are already
integrated in the HIMA standard power supply units.
Fig. 4: Principle of supply without decoupling
12
System Data
3.3 Wiring of the Subracks

If in a control operating with the Planar4 System the possibility of commu-
nication is not used, for the mechanical design a normal 19-inches sub-
rack is sufficient. With 32-pole connectors all functions of the system
except the communication can be applicated. For the basis wiring only the
following pins are used:
EL+ z30, d30

L- z32, d32
Error signal
(busbar) d28
Error signal
(NC contact) z26-d26
Fig. 5 shows the principle of the basis wiring of the subrack. For the rea-
sons of EMC it is advised against the loose wiring of the communication
connections in this subrack; for this purpose the subrack with bus PCB
should be used.
For safety reasons the reference pole L- must be made as a ring feeder to
the distributors and the subracks. Both ends of this ring line must be con-
nected to two separated terminals on the L- busbar. The L- must not be
fused.
The different circuits in the cabinets are fused with fuses 4A as a wire pro-
tection. They are included in the power distribution modules. These are
connected to a back-up fuse of preferably 16A. If the total current exceeds
the value of 16A, several back-up fuses with 16A must be provided. Back-
up fuses, distribution elements (e. g. busbars) and diodes for redundant
supplies are mounted on drawers for the 19-inches field. Detailed informa-
tion about these drawers is available from the brochure “Power Supply
and Current Distribution”.
For application of the communication of the Planar4 System the use of the
special subrack with bus PCB is recommended. The entire basis wiring
(voltage supply, fault signals and communication) is included in the PCB;
so there is more space available for the wiring of the functions. Module lo-
cation no. 21 is reserved for the communication.
Fig. 6 shows a depiction of the bus PCB principle. Additionally the depic-
tion shows with an example how the potential-free terminal blocks XG.2 to
XG.5, which are consisting of seven linked terminals each, can be used
for further wiring.In order to keep mechanical stress to the soldering points
low, the terminal blocks XG.1 to XG.6 should be pulled out from their sok-
kets before connecting or removing wires.
If in the subrack not all module locations are used, the pins of the contact
loop for the fault signal (z26-d26) must be linked or connected to the ter-
minals EC in the blocks XG.1 or XG.6.From terminal E the fault signal
ERR is available as a common signal for further processing.
13
System Data
Fig. 5: Basis wiring of a subrack without bus PCB
14
System Data
Fig. 6: Bus PCB of the subrack

principle depiction with wiring example
15
System Data
3.4 Electromagnetic Compatibility (EMC)

The modules of the Planar4 System meet the requirements of the EMC
guideline of the European Union. The data sheets and the modules there-
fore show the label.
Immunity
The severity level of the test is defined in the following standard:
EN 50082-2 Electromagnetic Compatibility (EMC), Generic Immunity

Standard Industrial environment
Standard Test Test value

NAMUR NE 210 Inrush current limiting Imax ≤ 15 x IN
5/93
IEC 1000-4-2 Electrostatic discharge Contact: 6 kV,
(DIN EN 61000-4-2) (ESD) clearance in air: 8 kV
IEC 1000-4-3 Radio-frequency interfe- 10 V/m
(DIN EN 61000-4-3) rence (RFI), traced
IEC1000-4-4 Burst (supply lines) 2 kV
(DIN EN 61000-4-4) Burst (data lines) 2 kV
IEC 1000-4-5 Surge pulse 1 kV symm.
(DIN EN 61000-4-5) (supply lines) 2 kV asymm.
IEC 1000-4-6 Radio-frequency interfe- 10 V
(DIN EN 61000-4-6) rence, conducted
Emmission
EN 50081-2 Electromagnetic Compatibility (EMC), Generic

emmission standard Industrial environment
EN 55011 Suppression of Radio Disturbances caused by

electrical appliances and systems
Die Baugruppen überschreiten nicht die Grenzwerte der Klasse B für die
Gruppe 1 und sind für den Einsatz im Industriebereich vorgesehen.
3.5 Ambient Conditions

The modules of the HIMA-Planar system are suitable for application under
the following ambient conditions:
Range of ambient temperatures prevailing

on themodules during operation -25...+70 °C
Admissible storage temperature -40...+85 °C
Admissible humidity
annual average ≤ 75 %
during 30 days of the year 95 %
during the remaining days 85 %
not exceeding the annual average
16
System Data
Limit of mechanical stress

Vibration / oscillation 10...150 Hz, 1 g
Shock 15 g / 11 ms
admissible mechanical stress for stationary non-vibrationless
devices or vehicles, but not fitted to a motor or on board of ships
Air pressure
operating altitudes up to 1000 m MSL
Note: Modules of the HIMA Planar4 System may be used also in altitudes
higher than 1000 m MSL, if there the reduction of the power dissipation
(and of the output loads at the same time) is regarded.
From 1000 m MSL the power load at nominal voltage must be reduced by
approx. 10 % per 1000 m additional altitude.
3.6 Definition of Signals and Standard Load Factors

The signal levels of the modules of the Planar4 System correspond to the
standards DIN 19238 (binary DC signal) and DIN 19240 (peripheral inter-
faces of electronic controls).
The input and output loads can be recognized by the standard load factors
indicated in the data sheets.
Designation of standard load factors:

F (Fan in (Fi) or Fan out (Fo)), indication of figure and letter F, e.g. 10 F.
There is no difference made between Fan in and Fan out, since it is ob-
vious whether this relates to an input load (Fi) or an output load capability
(Fo).
The values are summarized by the following table..
Designation Values according to DIN 19238

Standard load factor F = Fan
Designation within the HIMA data sheets Declaration of a number and character F 10 F
Note Fi = Fan In (input load) / Fo = Fan Out (output load capability)
Electrical value 1 F = 2 mA at 24 V (Ri = 12 kΩ)

Signal voltages on the inputs
0-Signal (L-Signal) -3 V...+5 V or open input

1-Signal (H-Signal) +13 V...+33 V
typ. operating point approx. +10 V

Signal voltages on the outputs
0-Signal (L-Signal) 0...+2 V

1-Signal (H-Signal) +16 V...+30 V
Note: The signals for the control of Planar4 modules must have a edge
steepness of ≥ 1 V/ms.
17
System Data
3.7 Short-Circuit Strength of the Outputs

The outputs marked k are short-circuit proof to L- and L+. According to
VDE 0160 (05.88), outputs may be de-signated as short-circuit proof if the-
re is no excessive temperature rise or other damage when a short-circuit
occurs for an indefinite time. When the short-circuit is eliminated, full
functioning must be restored without replacement of components. This is
not applicable, however, if the value of a fuse in the output circuit is lower
than the electronic short-circuit current limitation.
The short-circuit strength and immunity to damage of the inputs and out-
puts of the Type F modules is assured to L- and L+ without limitation. The-
refore during testing and commissioning, at any time the 1-signal can be
forced by applying L+ to an input and the 0-signal by applying L- without
having to note the state of the preceding output.
Due to short-circuits or applying of a signal as well the diagnosis and com-

munication subassembly (DCM) can indicate an error on the module. The
function of the module is not influenced, but the fault signal, however,
remains until the voltage supply of the module is switched off for a short
time, e. g. by pullin out the module and inserting again.
3.8 Current Consumption of Modules

The currents indicated under operating data in the data sheets apply to
functional modules, i.e. the current indications also include the input cir-
cuits and therefore the input currents. As a consequence the load of the
control outputs is automatically taken into account.
The control current consumption of wired systems is yielded from the total
of currents indicated under opera-ting data in the data sheets.
The current consumption of the power circuit is yielded from the total of
currents of the loads connected (lamps, solenoid valves, relays etc.).
18
Mechanical Design
4 Mechanical Design
4.1 Modules of the HIMA Planar4 System

Basis of the modules are printed circuit boards according to DIN IEC 326
(160 x 100 mm), made from glass-fibre reinforced epoxy resin. The tracks
are tin-plated and coated with a solder resist.
128.7
14 172 20
Fig. 7: Side and front view of a module
Depending on the type, on the front plate there may be included light emit-
ting diodes, switches, operating elements etc. The indicator lights shown
in the data sheets are designed as light emitting diodes. The type of the
module and the markings for display and operating elements is printed on.
By pushing down the mobile handle on the front plate the module can be
pulled out after having detached the fixing screws.
A male connector type F according to DIN 41612 is used as plug connec-

tor. The male connectors at the modules and the female connectors at the
subracks meet at least the requirement level 2 according to DIN 41612.
The contacting surfaces are hard gold plated.
The module data sheets indicates the space requirements:

3 U high 1 U (unit) = 44.45 mm
4 SU 1 SU (spacing unit) = 5.08 mm
4.2 Subracks
The modules can be arranged in subracks type BT 21 (with 21 slots),
available for 19-inches fields. The subracks can be fitted into frames or
racks featuring tracks of punched holes according to DIN 41494. In addi-
tion there are special subracks available with a bus printed circuit board
including a module location for a communication module and the entire ba-
sis wiring for voltage supply, fault signals and communication (cf. also
chapter “Wiring of the Subracks”).
19
Mechanical Design
4.3 Cabinets and Racks

For the construction of systems there is a standard selection of cabinets
with 19" frames available.
For further details of the cabinets refer to the brochure “Standard Cabinet
and Mechanical Construction”.
20
Wiring and Fusing
5 Wiring and Fusing
5.1 Colours of Wires

For the wiring of the voltage supply in the cabinet with single wires and for
solid-wire links the following colours are recommended and used by HI-
MA:
red (RD) L+, EL+ (24 V DC)
black (BK) L- (reference pole)
grey (GY) signal lines
brown (BN) circuits with U > 50 V
light blue (BU) intrinsically safe circuits
5.2 Wire Cross-Sections

Feeding of the HIMA Cabinets
An externally generated supply voltage 24 V DC must be fused also exter-
nally.
Inside the cabinet the wiring of the supply voltage is made in accordance
to the following table:
Current Terminal Wire cross- Wiring in the

(external fuse) size section cabinet
I ≤ 16 A 4 mm2 2.5 mm2 direct on potential

distributor
I > 16 A 10 mm2 6 mm2 on distribution

I ≤ 35 A drawer K . . . .
I > 35 A 35 mm2 16 mm2 on distribution

I ≤ 63 A drawer K . . . .
Cross-Sections in HIMA Systems

Wire cross-sections behind fuses are dimensioned according to the follo-
wing table:
Fuse Cross-section
4 A gL or T 1.0 mm2
10 A gL 1.5 mm2
16 A gL 2.5 mm2
25 A gL 4.0 mm2
35 A gL 6 mm2
50 A gL 10 mm2
63 A gL 16 mm2
Used equipment wire: type H07V-K
21
Wiring and Fusing
5.3 Fuses
There are two categories of fuses:
• Fuse cartridges
Here the standards DIN VDE 0636, DIN 49515 and DIN 49522 are
valid.
In HIMA systems generally only the following fuse cartridges are
used:
gL line protection
gR semiconductor protection
• Miniature fuses
(G fuses, 5 x 20 mm and 5 x 25 mm)
Here the standards IEC 127, DIN 41571 and DIN 41576 are valid.
The identification of the fuse tripping characteristic is made in the
classes
F quick-acting
T time-lag
The fuses available in the supply of the control voltage EL+ and the power
circuit voltage L+ are exclusively intended for line protection. For this rea-
son, fuses below 4 A are not required (on fuse modules). The subracks
with a bus PCB and the fuse modules may be protected using back-up fu-
ses with preferably 16 A.
The reference pole L- must not be protected by fuses in order to ensure

that the modules operate properly. For safety reasons the reference pole
L- must be made as a ring circuit to the distributors and the subracks. Both
ends of this ring line must be connected to two separated terminals on the
L- busbar. The modules of the Planar4 System are equipped with at least
two connections for L-.
The power supply unit is fuse-protected against short circuits at the sy-
stem supply. Here it is also admissible to have a fuse-protected negative
pole L- if it is ensured that the system is completely closed in itself and that
before the fuse there are no electrical connections to other systems.
5.4 Connecting the Field Cables

Basically, the field cables may be connected in various ways on the cabi-
nets or directly on the subracks:
• Terminals available on the cabinets or racks:
Terminal strips with continuous terminals are avail-able on the rear
side of the cabinet or rack. According to this traditional method the
internal lines are lead to the connecting points of the female con-
nectors available on the subracks on one side of the terminals with
the wires of the field cables connected on the other side of the ter-
minals.
• Connectors in the cabinets or racks:
Connectors are used instead of continuous terminal rows and they
enable a quick connection of the system on site when using preas-
sembled cables.
22
Quality Management
6 Tests within the Quality Management

The quality assurance is based on DIN EN ISO 9001.
All modules of the HIMA Planar System F, as well as the control cabinets
and systems wired by HIMA are subject to extensive functional tests be-
fore delivery.
6.1 Final Product Testing of Modules

Each individual module is subject to a complete final test. These tests are
carried out for the modules using automatic test equipment or special te-
sting devices. A specific test program is elaborated for each individual mo-
dule. Specific devices for each individual module provide for measuring
electrical values at given locations within the circuit. These measurements
do not only compare the voltage levels but also register their course in
time and compare them to the target data.
6.2 Factory Testing of HIMA Control Cabinets

Factory testing of HIMA control cabinets or of the systems wired by HIMA
is effected in two stages: mechanical check and function test.
6.2.1 Mechanical Check
Completeness
It is checked whether the parts have been fitted in completely and properly
using the unit list and the design plan
Wiring check
Conductor cross-sections, colours and fuse protection of supply 24 V DC
according to wiring documents
Laying and connecting of intrinsically safe circuits
Laying of lines featuring voltages not inherent to the sys-tem

Checking of solder joints, screwed and terminal connections, as far as
possible
Checking live conductors and wiring of busbars for short-circuit and pola-
rity
Function of the built-in fans
Labelling
Attaching and designating the modules and the mounting parts in com-
pliance with HIMA standard
Attaching type, company and test plates
23
Quality Management
Mechanical parts
Checking of screwed connections
Checking the colour of the cabinets and type of painting
Checking the doors whether they close properly
Locking the swivel frame for dispatch
Grounding of all metal parts
6.2.2 Function Test

Function tests are carried out on the individual HIMA control cabinets
using the circuit diagrams.
They include the electrical signals of the input terminals, the functions and
the output terminals.
The binary and digital input signals are simulated on test boards using
switches or keys. The binary output signals are indicated by lamps. Te-
sting of valve and motor functions is effected using special modules (simu-
lation of functions).
Analog input signals simulated by using voltage or current sources.

Similar functions (e.g. in the case of annunciator sys-tems and isolating
amplifiers) are subject to functional random testing; wiring is checked
completely by line continuity tests.
The testing scope does not include an interconnection of several control

cabinets. Interconnection is made only upon request and will be charged
additionally.
Factory testing of switch cabinets is effected together with the modules

that are delivered with the cabinets.
During the factory acceptance test the doors and covers of control cabi-
nets are not mounted yet due to possible modifications. They will be
mounted before dispatch.
6.2.3 System Test at Increased Temperature

The function of HIMA control cabinets or wired systems can be tested in a
special room at increased temperatures of ≤ 50 °C (± 5 °C). Depending on
the size of the room a maximum of up to ten standard cabinets including
test equipment can be tested simultaneously.
Testing of cabinets at increased temperatures (Special test: Heat Soak

Test) is made upon request only and will be charged additionally.
24
Engineering Notes
7 Engineering Notes
Edge steepness of the signals
The signals for the control of Planar4 modules must have a edge steep-
ness of ≥ 1 V/ms.
The safety function and the diagnosis of a module are independent from
each other. With a too small edge steepness of an input signal there arises
the possibility of a module error diagnosis.
Wired-OR logic
Wired-OR logic functions are not admissible for the outputs of logic modu-
les, as this can result into the diagnosis of a module error. OR functions
must be realised with OR elements.
For this purpose power outputs have a second output decoupled with a di-
ode. A break of the diode, however, is not detected in this application.
Time delay with RC element

RC elements for the time delay of signals are not admissible, as this can
result into the diagnosis of a module error (cf. above, “Edge steepness of
the signals“).
For time delay functions suitable modules must be used.
Ring feeder for reference pole L-

For safety reasons the reference pole L- must be made as a ring feeder to
the distributors and the subracks. Both ends of this ring line must be con-
nected to two separated terminals on the L- busbar. The L- must not be
fused.
Operating voltage
In order to ensure the correct function of the control, the operating voltage
24 V DC must be monitored by means of a voltage measuring device. If
the voltage goes down to a value of ≤ 18 V, the supply voltage of the con-
trol or at least of the output modules must be cut off.
Fault signals of modules

Due to manipulations on the wiring side of a subrack the diagnosis and
communication subassembly (DCM) can indicate an error on a module.
The function of the module is not influenced, but the fault signal, however,
remains stored until the supply voltage is switched off for a short time (e.
g. by pulling out the module and inserting again).
Engineering notes for safety functions

can be found in the chapter “Safety Controls with the Planar4 System” in
this manual.
25
Engineering Notes
For your notes
26
Start-Up, Maintenance, Repair
8 Start-Up, Maintenance, Repair

In order to avoid reduction or endangering of the safety of modules of the
Planar4 System and their functions, before starting work in start-up,
maintenance, modifications and repairs the following chapters “Start-up,
Maintenance, Repair”, “Safety Controls with the Planar4 System” and
“Certification of the Planar4 System” have to be regarded carefully as well
as all notes in the data sheets of the modules.
8.1 Start-Up
The control cabinets are delivered with the modules plugged in and fixed
with screws. They have been tested with these modules in the factory, so
that the following tests can be restricted to the correct external installation.
The modules themselves have no coding. Only the correct allocation of

the module type to the slot must be regarded according to the labelling.
The existing fuse modules including fuses have to be checked for comple-
teness.
For pulling out or inserting of modules of the Planar4 System it is not re-
quired to cut off the power supply, but here any possible effects onto the
entire function of the control must be regarded.
8.1.1 Testing the Inputs and Outputs for External Voltage

and Earth Faults
Impermissible external voltages (especially e. g. 230 V AC to earth or L-)
can be checked with a multimeter. It is recommended to check each single
connection for impermissible external voltage.
When testing the external cables for insulating resistance, short circuits
and wire breaks, the cables must be disconnected at both ends in order to
avoid defects or damaging of the modules with excessive voltages.
The testing for earth faults is made the field cables are connected to the
control cabinet. The supply voltage to the sensors and the negative pole
for the actuators must be disconnected. If the negative pole is used for
earthed operation, the earth connection must be interrupted during testing
for earth faults. This also applies for the earth connection of possibly exi-
sting earth fault testing facilities.
The checking of each connection against earth can be made a resistance
meter or a special testing device.
In this state of the system testing is only permissible for individual lines or
a group of lines insulated against earth, but not two lines among themsel-
ves. Otherwise there is a high risk of damage. Testing with high voltages
is not permissible as well.
The standard for test voltages and insulating resistance is EN 50178 (VDE
0160).
27
8.1.2 Connection of Power Supply

The modules are fixed with screws in the subracks when delivered. Befo-
re connection of the power supply 24 V DC it has to be checked for correct
polarity, level and ripple. With polarity reversal the fuses on the modules
will blow, and they are not exchangeable by the user.
8.1.3 Modifications
During work at the control system the operating voltage must be switched
off if possible, as short-circuits in the range of the signal wiring may endan-
ger the safety funtions of the control system.
For soldering work the use of a a low voltage soldering iron with an isola-
ting transformer is mandatory. Working with soldering irons directly con-
nected to 230 V AC may result in damage of the semiconductors. This
applies even when the operating voltage of the control is switched off.
For other types of wiring technology e. g. termi-point the use of a suitable

tool is necessary.
For modifications in the area of power supply the wire cross-sections must
be regarded (cf. chapter “System Data”). The connection of the reference
pole L- to the subrack or to other devices supplied with 24 V DC must al-
ways be made as a ring line wiring.
Due to short-circuits, applying of a signal or similar manipulations on the

wiring side of a subrack the diagnosis and communication subassembly
(DCM) can indicate an error on a module. The function of the module is
not influenced, but the fault signal, however, remains stored until the sup-
ply voltage is switched off for a short time (e. g. by pulling out and inserting
the module again).
8.2 Maintenance
The HIMA Planar4 System is designed for industrial conditions. Electronic
components have a very low failure rate after the initial operating phase of
approx. 500 to 1000 h. This initial operating time is already attained during
the period of functional tests at the factory or during start-up of the system.
Wear can only occur in relay outputs with heavy loads and/or those which
are frequently switched. These modules should be replaced as a preven-
tive measure when the number of switching cycles according to the data
sheet is reached.
For safety related relay outputs the possibly stipulated testing intervals
have to be regarded. More detailed instructions are listed in the data
sheets of the modules or in the “Report to the Certification”.
Defective modules of the Planar4 System are detected by the intgrated

self-diagnosis and immediately reported to an equipment suitable for eva-
luation (cf. chapter “The HIMA Planar4 System”). A defective module is
identified by a red light emitting diode ERR and can be replaced at once.
For replacing the module it is not necessary to disconnect the voltage sup-
ply.
28
A module detected to be faulty must be removed or replaced immediately,

as one or several errors occuring additionally within the module may
endanger the safe state of the system.
If an input module is equipped with a line monitoring then also the lines to
the sensors are tested, and external faults are indicated by light emitting
diodes and additional signal outputs of the module. This is also valid for
output modules with monitoring of the fuse in the output circuit. In this case
the external line must be checked but the module may not be replaced.
For power supplies and decouplings it is recommended to replace electro-

lytic capacitors approximately every five years.
Other maintenance work is not required for the Planar4 System.
8.3 Electrostatic Discharge (ESD)

Repair or maintenance work on supply and signal lines of a Planar4 Sy-
stem control may only be executed by qualified personnel with consi-
deration of all ESD protective measures. Before direct contact of these
lines the maintenance personnel must be discharged electrostatically.
8.4 Repair of Modules

The repair of modules cannot be made by the plant operator, as there are
special computer programs and equipment necessary. Faulty modules
should be tested by the operator and then be sent to HIMA with a short
fault description.
For repairs performed outside our influence, our responsibility for the pro-
duct concerned expires. This is of especial importance in those cases
where the product responsibility is fixed upon the manufacturer by legisla-
tion and/or ordinances.
Equipment possessing a safety certificate is safety-relevant; it is marked

with a TÜV safety certification number. According with the relevant autho-
rity the legal product responsibility remains with the manufacturer.
In order to retain the validity of safety certificates, the repairs of safety-re-
lated modules of the Planar4 system must be performed only at HIMA.
For all other non-safety-related modules the following ordinances are va-
lid:
1. Equipment with (Ex)i circuits

possessing an EC Prototype Test Certificate:
In accordance with the regulations, such equipment is clearly marked

(EX sign on the front plate, Ex data on the connector strip). The
conformity certificate is enclosed to the respective data sheet.
29
The German ordinance on electrical systems in explosion-hazard

rooms (ElexV) lays down in §9 Repairs (1) that a piece of equipment
which has been repaired in connection with a part on which the explo-
sion protection depends, must be checked and confirmed by an expert
for perfect condition in safety-related functions before being used.
According with § 9 (2) of this ordinance ElexV this requirement may be

inapplicable if the equipment concerned has been repaired by the ma-
nufacturer.
2. Equipment in systems with liquids dangerous to water under the Ger-

man Water Equilibrium Act (WHG):
This act, as amended on 30th September, 1986, lays down that repairs
may be performed only by specialized companies within the meaning
of § 191 of the act. If the user concerned is not certified under § 191
WHG, it is impermissible for him to perform repairs on this equipment.
8.5 Supply of Internal Documentation of the Modules

Internal circuit diagrams, face plans and parts lists relating to modules and
devices are considered to be internal documents and do not form part of
the general HIMA documentation and plant documentation. They are only
needed for repair which may not be made by the plant operator as men-
tioned above, and so they are no subject of delivery.
The system manual with the data sheets provides for sufficient understan-
ding of the module functions and for the planning of controls with modules
of the HIMA Planar4 System.
8.6 Service and System Training

Appointments can be made with the Service Department concerning start-
up, tests or modifications of HIMA controls, as well as the dates and extent
of the work to be done. The invoices for the service work are based on the
extent of work and on set rates.
HIMA makes special training for the safety controls of the Planar4 System
which usually takes place in our premises. Additionally training on site is
offered on the customer's premises. The current training program with de-
tailed information and dates can be obtained on request from HIMA.
30
Safety Controls
9 Safety Controls with the Planar4 System
9.1 Reliability
Reliability is the characteristic of a technical equipment to fulfil a required
function under given conditions for a certain period of time. Mostly this is
not longer possible if one component has failed.
A parameter for reliability is the MTBF (Mean Time Between Failure). It

shows the mean operating time during which no failures occur. The MTBF
can either be calculated from the reciprocal value of the sum of component
failure rates, or it can be calculated statistically.
A high reliability (large MTBF) is, however, no criterion for the safety and
als not the only criterion for the availability of a system.
Important parameters for the statistical calculation of the MTBF are:
Failure ratio:
The failure ratio is the percentage of faulty components during an opera-
ting period, shown in percent.
number of failures
Failure ratio = ------------------------------------------------------------- • 100%
number of components
Failure rate:
The failure rate l is the failure ratio divided by the operating time and is gi-
ven in h or in FIT (failure in time). One FIT means one failure within 109
component hours.
number of failures
Failure ratio = -----------------------------------------------------------------------------------------
number of components • loadtime
The failure rate depends on the operating time of the system. Fig. 8 shows
this dependency. To calculate the MTBF the time of the constant failure
rate is used when the infant mortalities (after 3-4 weeks of operation) are
over.
Range t0...t1:
Infant mortalities
Range t1...t2:
Random failures
Range t2...t3:
Failures due to wear
t0 t1 t2 t3
Fig. 8: Failure rate depending on time
The infant mortalities of the modules (components) usually occur during

the test and start-up period, so they are not relevant for operational appli-
cation. Electronic components are only subject to infant mortality or ran-
dom failures. Failures due to wear are only relevant for mechanical
components (relays) and for electrolytic capacitors in power supplies.
31
Safety Controls
Calculating the MTBF of modules which is made as a HIMA standard with

the failure rates indicated by the component manufacturers will automati-
cally result in a lower operating time, as the manufacturer failure rates are
indicated for full load on the components (worst case). To obtain a realistic
value the result must be multiplied by a correction factor.
The possibility for statistical determination of the MTBF of an entire system

shows the following example:
During five years the operating times of a plant were registered. Its control
cabinet is fully equipped with 200 modules. The following operating times
were found:100 h, 1 500 h, 13 500 h, 8 000 h, 20 000 h
The total operating time (excluding the time for repair) was T = 43 100 h.
The plant had a total of n = 5 failures.
T 4300 h
MTBF = --- = ------------------ = 8620 h (approx. 1 year)
n 5
The reliability alone, however, is no statement about the safety of a sy-

stem. Unreliable systems can be safe too, if the failures result every time
in the safe state.
9.2 Availability
Definition according to VDI/VDE 2180:
The availability A is the probability to find a system in a functioning state

at a given point of time.
Calculation of availability according to VDI/VDE 2180:

MTBF
A = ------------------------------------ • 100%
MTBF + MDT
Total operating time = MTBF + MDT
MDT = Mean Down Time
The MDT is also frequently called "mean repair time", and it consists of the
mean fault detection time plus the mean fault correction time.
Due to the self-diagnosis of the modules of the Planar4 System there is no

fault detection time, and the time for the fault correction is limited to the ex-
change of the module signalized as being faulty. So the MDT is calculable
unlike in systems without self-diagnosis, and the replacing of modules can
be made by personnel without any specific knowledges.
32
Safety Controls
The availability can additionally increased by parallel arrangement of mo-

dules. The MTBF of a redundant system then is determined essentially by
the MDT:
MTBF mono 2
MTBF red = ----------------------------------
-
2 • MDT
9.3 Safety
If a system has a high reliability and availability, this does not necessarily
mean it is safe. In case of failure hazardous states may occur, as no state-
ment can be made on the reaction of the output signals of electronic com-
ponents in such a case. A system is safe exactly when in case of each
possible fault the affected part of the plant is put to a safe state. In e. g.
ESD systems this is the deenergized state of the output signals, so that
line breaks as well as the failure of the power supply are regarded as non-
dangerous faults.
For the term of safety there are numerous definitions that have been
worked out by different boards. All definitions have in common that safety
means a sufficient protection from danger. In the DIN 31000 standard do-
cument, part 2, safety is defined as a situation in which the risk is not hig-
her than the limit risk. This also means that absolute safety cannot be
achieved in technology.
Limit risk: the highest acceptable risk

Safety: lower risk than limit risk
Danger: higher risk than limit risk
Fig. 9: Safety and danger as expressions of different risks
A so-called remaining risk (danger) exists in each “safe plant” (as shown
by the subdivision of risks in fig. 9), as not all faults can be foreseen.
9.3.1 Safety Standards and Guidelines

The safety standards like DIN V 19250, DIN V VDE 0801 and IEC 61508
look at the entire complex of safety, independently of specific applications.
Requirement classes and the most general measures for the satisfaction
of a requirement class are defined, depending on the risk involved. It is
only in the group standards that possible measures are explicitly descri-
bed in terms of their effectiveness and the time which they might consume.
33
Safety Controls
Product standards are included here. This division of standards and gui-
delines corresponds to the CEN classification which is valid in Europe
since 1992.
Standard Title Edition

DIN VDE 0100 Regulations for the installation of power systems 12.90
DIN VDE 0105 Operation of power installations 07.83
General rules
DIN VDE 0106 Protection against shock 11.86
part 101 Basic requirements for protective separation
DIN VDE 0110 Coordination of insulation for electrical operation facilities 01.89
in low voltage switch gears
Part 1: Principal rules
Part 2: Measuring of air and creeping distances
DIN VDE 0116 Electrical equipment of furnaces 10.89
DIN EN 50178 Electronic equipment for use in electrical power installati- 04.98
(VDE 0160) ons and their assembly into electrical power installations
DIN VDE 0435 Electrical relays 04.88
EN 60742 Isolating transformers and safety isolating transformers 1995
(VDE 0551)
DIN V VDE 801 Principles for computers in safety related systems 01.90
EN 60950 Safety of information technology equipment including 1988

(DIN VDE 0805) electrical buisiness equipment
DIN V 19250 Requirement categories and basic safety considerations 05.95
DIN V 19251 Process control technology, MC protection equipment 02.95

Requirements and measures for safe guarded functions
DIN 31000-2 Genaral rules to construct safety related technical 12.87
facilities
Part 2: Terms of safety technology, basic terms
EN 298 Automatic gas burner control systems for gas burners and 1993
gas burning appliances with or without fans
EN 50081 Electromagnetic compatibility (EMC), Generic emsssion 1993
part 2 standard,
Industrial environment
EN 50082 Electromagnetic compatibility (EMC) Generic immunity 1995
part 2 standard,
Industrial environnment
EN 55011 Radio interference suppression of electricalappliances 1991
and systems
IEC 68 Basic environmental testing procedures
Part 2-1: ColdPart 05.94
2-2: Dry heat 05.94
Part 2-3: Damp heat, steady state 1969
Part 2-6: Vibration, sinusodial 03.95
IEC 61508 Functional safety; safety related systems
VDI/VDE 2180 Safeguarding of industrial processing plants by means of
instrumentation and control technology
part 1 Introduction, terms, designations 04.86
part 2 Calculation methods for reliability characteristics of safety 04.86
facilities
part 3 Classification of measurement and control systems 12.84
part 4 Construction and testing of protection devices 07.88
part 5 Building and installations requirements for safeguarding 12.84
measurement and control equipment under emergency
conditions
34
Safety Controls
Standard Title Edition

VDI/VDE 3541 Interlocking and sequencing systems with agreed safe- 10.85
guarded function
VDI/VDE 3542 Safety terms for automation systems 12.88
Table 1: Excerpt from standards and guidelines edition 1998
9.3.2 Module Test according to DIN V 19250

All safety-related modules of the Planar4 System are tested according to
requirement classes (RC) in DIN V 19250. The system concept is desi-
gned for RC 7.
9.3.3 Module Test according to IEC 61508

Nationally valid as a basis standard for the safety of process control pro-
tection equipment is DIN V 19250, internationally the standard IEC 61508;
the modules of the Planar4 System are tested according to it as well.
The safety levels of the IEC 61508 standard are defined as SIL (Safety In-
tegrity Level) 1... 4. The table below serves as a cross reference to the re-
quirement classes according to DIN V 19250.
DIN V 19250 IEC 61508

DIN V VDE 0801
Requirement classes RC Safety Integrity Level SIL
Low demand mode of High demand or continuous
operation mode of operation
1
2
1 (<10-1) 1 (<10-5 h-1)
3
4 2 (<10-2) 2 (<10-6 h-1)

5
3 (<10-3) 3 (<10-7 h-1)
6
7 4 (<10-4) 4 (<10-8 h-1)

8
Risk analysis: Basis safety standard
R=SxH safety-related life cycle
S Damage plus requirement levels
H Frequency
H = f (A, G, W) Example: Example:
A Duration of stay
G Hazard prevention 10-3 means the probabi- 10-7 means the probability
W Probability of un- lity of one hazardous of one hazardous failure per
desired event failure in case of request hour
without I & C
equipment
35
Safety Controls
9.4 Functional Principles of Safety-Related Modules

Individual operational items in modular systems are called safety-related
modules when they have a corresponding safety certificate from the TÜV
test authority.
9.4.1 Module Safety by Fail-Safe Principle

Safety-related modules are modules which in case of a component failure
are put to the state defined as safe on the output. In the Planar4 System
the basis of the safety function is the closed-circuit principle; here the state
with the lowest amount of energy is defined as safe.
Unlike the modules which are not safety-related (internal processing with
DC voltage) for these modules internally the dynamic principle is used: the
input and output signals are still static DC voltage signals, but the internal
processing of the signals is made dynamically via an AC coupling.
The detailed description of this principle can be taken from the chapter
“The HIMA Planar4 System”.
9.4.2 Module Safety by Comparison Functions

The safety of module due to comparison functions (e. g. 1oo2 micropro-
cessor systems) is guaranteed with the use of a two-channel and synchro-
nous operating processor structure and cyclic self tests. Microcontrollers
are used as central processor units.
The task of the self-test software is to detect all failures by using of special
measures (like high-quality tests of the input and output circuitry) which
may not be detected via the system structure (two-channel) and may re-
sult in a dangerous operational state.
This safety principle is used e. g. for time-delay function modules.
9.5 Safety Circuits
9.5.1 Closed-Circuit Principle

In the safety-related controls of the Planar4 System always the closed-cir-
cuit principle is valid as basis, i. e. with wire breaks or defective safety-re-
lated modules the control is set into the state defined as safe
(deenergized). This principle must be continued also in the plants control-
led with it.
9.5.2 Latching Circuits (Memory)

Using the closed-circuit principle in safety related controls the binary me-
mory is replaced by a latching circuit. For these circuits should be ensured
that the self-holding function is released both in case of a switch-off and in
case of a fault (also line break). The technical realisation of this in the cir-
cuit must be the dominant reset (OFF with 0-signal).
36
Safety Controls
Fig. 10: Latching Circuits
Note
Due to the internal circuit structure of the modules the feedback path of the
latching circuit should be connected to the input marked “d..” or in case of
more inputs to that one with the highest number.
9.5.3 Negation (Blocking Element)

In safety related circuits the application of inverters is always highly pro-
blematic , as principally the input of a module cannot distinguish between
0-signal and an open line (line break). This fact is true for all hard-wired
systems, also for relay circuits. So the use of an inverter directly in a safe-
ty related circuit is not permissible; the negation of the signal must be
made at any other suitable place, e. g. by application of an opening or clo-
sing contact (regarding the closed-circuit-principle), or for proximity swit-
ches by a specially designed mechanical construction of the damping
element.
If in a safety related control both the direct signal as well as the inverted
one are processed, the use of a safety-related blocking element is man-
datory. It is important then to take the direct signal behind the blocking
element from the direct output, as the internal circuit arrangement of the
blocking element excludes a simultaneous 1-signal (also overlapping) on
both the inverted and on the direct output.
Fig. 11: Signal inversions in safety related controls
In the logic in fig. 12 a line break in front or behind the time delay function
or an error within the time function would prevent the switching-off of out-
put A1 via E2.
The wiring with an inverter contains a blocking element for the signal input
E2 and a changed time delay function (delay-off instead of delay-on). But
also here a line break in front of the blocking element prevents a switching-
off of output A1, whereas A2 nevertheless is switched off.
37
Safety Controls
Fig. 12: Problematic nature of signal negation
9.5.4 Input Circuits for Inductive Sensors (proximity switches)

The safety-related input modules of the Planar4 System correspond to
DIN 19234 standards for DC interfaces, their inductive sensors (proximity
switches) and switching amplifiers. The safety-related evaluation of a pro-
cess signal, however, is obtained only in connection with a safety-tested
proximity switch.
Instead of a proximity switch also a contact with a serial and a parallel re-
sistor can be used. These resistors must be installed directly at the contact
to detect line faults. The values of the resistors are shown in the data
sheets of the related input modules.
For the use of non-safety-related proximity switches (according to DIN

19234) there is one possibility to evaluate the process signal according to
the redundancy principle via two separated proximity switches and two
channels of an input module (or via two modules); both the output signals
must be combined by an AND element. The notes in the data sheets of the
related module have to be regarded.
As the electrical and mechanical switching points of the sensors may di-
verge, the application of an equivalence monitoring with time delay is ne-
cessary to prevent undesired switching functions. The expense can be
reduced when the safety-related module with 2oo3 selection elements is
used for monitoring the signals. Additionally the function has to be tested
in regular intervals, e. g. one time per year.
9.5.5 Coupling to Safety-Related Circuits

It is possible to transfer signals from safety-related circuits to other non-
safety-related modules. This may be an advantage because of economi-
cal reasons. But the non-safety-related modules must have non-interac-
ting inputs to prevent a feedback to the safety related circuit in case of an
internal fault of this non-safety-related module.
All inputs of the safety-related modules of the Planar4 System are non-in-
teracting.
If other modules which are not non-interacting are used for coupling to
safety circuits, the non-interacting function must be guaranteed by the in-
sertion of an OR element branch (cf. fig. 13).
38
Safety Controls
Fig. 13: Coupling to safety-related circuits
39
Certification
10 Certification of the Planar4 System

Safety related controls which in case of failure may cause considerable
damage are subject to strict tests. The safety related modules used in the
HIMA Planar System have all undergone individual TÜV type approval
tests. The succesful passing of the tests was certified for each module.
10.1 Basis of the Certification

For the tests to get the certification different regulations are applied. De-
tailed information about that can be taken from the Report to the Certifica-
te.
The TÜV test centre simulates faults like short circuits and interruptions.
The test result has to demonstrate that the safety function of the HIMA mo-
dule remains in case of a not detected single fault, and even also if up to
two additional faults occur. The probability of occurance of a fourth failure
is considered as being sufficiently remote.
Due to the high density of circuit elements a complex effect of faults is ex-
pected in the integrated circuits. Inevitable faults resulting from this are ta-
ken into account during the test.
Besides this, the module is submitted to an environmental test. The air and
creeping distances must follow DIN VDE 0110.
10.2 Report to the Certicicate

The Report to the Certificate of the Planar4 System contains detailed in-
formation about testing and certification requirements and a listing of the
tested modules. Additionally there are listed restrictions (e. g. proof check
intervals) which must eventually regarded during operation of the modu-
les. The report is available on request.
10.3 Notes to the Electrical Equipment of Furnace Controls

according to DIN VDE 0116
1 Circuit breaker for circuits with voltages ≥ 50 V
A manually operated circuit breaker has to be provided for each burner or
for a group of burners interrupting circuits with voltages > 50 V. This circuit
breaker has to be mounted outside the control cabinet if not specified
otherwise.
2 Emergency switch-off and main switch

2.1 Emergency switch-off
The ermergency switch-off signal has to be handled as an additional
switch-off signal. The number and the function of emergency-off signals
are to specify. Use of push-buttons requests special circuits (e.g. latching
circuits).
In hard-wired safety-related controls these signals belong to the shut-

down circuits.
40
Certification
2.2 Main switch

A main switch has to be provided on site out of the cabinet if not specified
otherwise.
3 Earthing of auxialiary circuits

An earthed as well as a non-earthed operation is permitted. Non-earthed
operation is preferred in reason of a higher availability.
3.1 Non-earthed operation

An insulation monitoring has to be provided for non-earthed operation.
3.1.1 Supply of the control cabinet 24 V DC

The insulation monitoring is to be provided outside of the control cabinet.
An insulation monitoring device is also requested for control circuits (out-

put circuits) with floating or fused contacts and voltages different from 24
V DC (mainly 230 V AC). A specification of the insulation monitoring de-
vice makes only sense when the other voltages are used only for the ope-
ration of the control in question and are electrically isolated from the mains
supply
3.1.2 Supply of the control cabinet with voltages > 24 V DC

Mainly with power supplies 230 V AC/24 V DC
The external power supply for control circuits with floating or fused con-
tacts has to be monitored outside of the control cabinet if this power supply
is not earthed.
The external supply of control circuits with neutral or fused contacts requi-
res a separate control transformer and a separate insulation monitoring if
the voltage is not earthed. If not specified separately an earthed operation
of these control circuits is assumed and no insulation monitoring is provi-
ded.
3.2 Earthed operation

The negative pole L- has to be lead on earth. The connection to earth must
be removable and has to be provided directly at the power supply (control
transformer).
The earthed operation guarantees defined signal states. However, a short

circuit to the earth will mainly result in a switch-off of the signal circuit or a
cut-off of the fuse in question.
41
Communication
11 Communication
The communication module at module location 21 of a Planar4 subrack
enables the data transfer to other systems via an RS 485 interface (MOD-
BUS, Profibus-DP) or Ethernet 10BaseT (OPC with protocol TCP/IP). De-
pending on the type of data transfer different types of communication
modules are used.
The following types of data can be transferred:
Type of data MODBUS Profibus-DP Ethernet (OPC)

RS 485 RS 485 10BaseT
BOOL: • • •
State of modules, state of module inputs and outputs
WORD / Ubyte: Type of module, actual values, limit values • • •
Events •
(Signal changes of inputs and outputs with date and time)
Time synchronization •
11.1 Communication via MODBUS Protocol

The MODBUS protocol is designed as a master-slave system for a serial
data transfer via a bus, and it was defined by Gould Modicon Inc.
The default setting is 1 stop bit, parity bit even and 9600 baud; the com-
munication module enables also 19 200 and 57 600 baud.
The HIMA systems only have the RTU (Remote Terminal Unit) mode of
transmission. The transmission is asynchronous with 8 bits and CRC error
check.
The RTU data transmission mode usually has the following structure:
Start Slave no. Code Data Error check End of

telegram
T1 T2 T3 1 byte 1 byte ∗ 2 bytes T1 T2 T3
∗ The number of bytes depends on the function, the quantity of addresses and data
Start, end Start of transmission resp. end of transmission is identi-

of transm. fied by a pause of 3.5 characters (bytes) (T1 T2 T3)
Slave Address of the slave system:

slave number, setting on the communication module
Code Function code: Reading of data, events
Data They comprise start address (area code and basis

address), quantity of adresses and data depends on
function, cf. definitions in the MODBUS protocol
Error check CRC code (Cyclic Redundancy Check), which is

automatically generated by the transmitting system
42
Communication
For the Planar4 System communication the following functions can be

processed with the MODBUS protocol:
– Reading of variables like inputs, outputs, actual values, limit values
– Reading of events
– Time synchronization
Binary signal changes of inputs and outputs are recorded as events. The-
refore events recorded in the same scanning cycle have the same time
stamp. The scanning cycle is ≤ 4 ms.
Events can be read (reading from the buffer on the communication modu-
le) with special function codes not defined in the original MODBUS proto-
col or with standard codes.
Each MODBUS communication module in a subrack of the Planar4 Sy-

stem is a slave in a RS 485 network. The slave number is defined by me-
ans of a switch on the communication module (cf. data sheet).
Design of the RS 485 Bus System
The quantity of slaves connected to a bus segment is limited to 31; by me-

ans of repeaters the system can be extended to four segments. With that
the quantity of addressable slaves is limited to 124.
The MODBUS master receives the desired information from the modules
of the Planar4 System by means of slave number, function code and
addresses.
A redundant design of the RS 485 bus system is not possible, as in each

subrack only one communication module can be used, and this module
has only one interface.
43
Communication
Function Codes
For the Planar4 System the following function codes are realized:
1 Reading the status of one or several binary values, e. g. inquiry for the state
of a module, input and output signals
3 Reading the status of one or several digital values, e. g. inquiry for the type of
a module, actual value of a time delay, residual delay times, limit and actual
values of limit monitors
6 Time synchronization
65 Scanning of events:
66 binary signal changes with time
67 (free codes in the original MODBUS protocol)
70 Time synchronization
11.1.1 Addresses
The addresses depend on the module location in the subrack and on the
requested information. For each module there are 256 addresses reser-
ved. The address A of the information of a module is determined as fol-
lows:
A = p ∗ 256 + n
p module location in the subrack; for the 1st location p = 1
n relative address of the information within a module
(cf. tables in the data sheets)
11.1.2 Reading of Data

For the reading of data the following function codes are realised:
Code Function
1 Reading the status of one or several binary signals (type BOOL)
3 Reading the status of one or several digital signals(type WORD)
With the function code 3 it is possible to transfer all information of the mo-
dules of one single subrack within only one telegram. For this function al-
ways 84 digital values (words) must be required according to the 21 inputs
of the communication module.
By using the starting addresses either 2000H, 3000H or 4000H it is deter-

mined which of the data are required. The data depend on the type of the
module. For module locations not in use the values 0 are transferred.
The master system must be able to interprete the received data, as they
contain a mixture of binary and digital values of the modules (types BOOL
and WORD).
44
Communication
11.1.3 Events
The communication module generates events of all binary input and out-
put signals of the modules. The signal changes are recorded, and an
event number (depending on the module location and the signal on the
module) with time is stored in a buffer. Events recorded in the same scan-
ning cycle have the same time stamp.
For each module there are 32 events reserved. The event number E of the
information of a module is determined as follows:
E = (p-1) ∗ 32 + n
p module location in the subrack; for the 1st location p = 1
n relative number of the event within a module
(cf. tables in the data sheets)
A maximum of 1024 events can be stored in the buffer. Two master sy-
stems can scan the events.
11.1.4 Reading of Events

For the reading of events the following function codes are used:
Code Function
65 Reading event values (status of the events without time)
66 Reading new events (address, status, time)
67 Request to repeat the last transmission
Reading with function code 65

With function code 65 the binary input and output signals of the modules
are transferredwithout the time. For module locations not in use the values
0 are transferred.
Function code 65
Slave Code Bytes Starting address Quantity of events CRC
1 byte 1 byte 1 byte 2 bytes 2 bytes 2 bytes
9 always 0 always 640
Response of the slave
Slave Code Bytes Event values module 1 ... Event values module 20 CRC
1 byte 1 byte 1 byte 4 bytes ... 4 bytes 2 bytes
Function code 66: Reading new events

A maximum of 8 events (64 bytes) is transmitted at the same time.
Function code 66
Slave Code CRC
1 byte 1 byte 2 bytes
45
Communication
Response of the slave if there are no events
Slave Code Qty. of bytes CRC
1 byte 1 byte 1 byte (0) 2 bytes
Response of the slave if there are events
Slave Code Bytes Event Event ... Event CRC
1 byte 1 byte 1 byte 8 bytes 8 bytes ... 8 bytes 2 bytes
Structure of an event
Event no. Event value ms ds s min h
2 byte 1 byte 1 byte 1 byte 1 byte 1 byte 1 byte
0 oder 1 0...99 0...9 0...59 0...59 0...23
Function code 67: last events transmitted

Code 67 is only possible after Code 66, if the master system has not re-
ceived a correct response to code 66. It makes the slave system repeat its
latest response.
Function code 67
Slave Code CRC
1 byte 1 byte 2 bytes
Response of the slave like at code 66, if the previous code was 66, otherwise
Slave Code Error code CRC
1 byte 1 byte 1 byte (0) 2 bytes
After a new start or buffer overflow of the slave system code 65 should be
sent. In normal operation code 66 resp. 67 has to be sent cyclically by the
master system.
Error messages with event checks
Code Meaning
1 Code 67 was not preceeded by code 66
2 With code 65 “Starting address” is different from 0 or the number of events is

not defined correctly
46
Communication
11.1.5 Events Checks via Standard Codes 1, 3

The checks realized by the codes 65, 66, and 67 can also be performed
by the standard codes 1 and 3.
The readout of events can also be performed by 2 master systems using

different base addresses during readout. The first master system uses the
starting address 8960 and the second the starting address 9216. The
events are read out from the same event buffer.
Event check with Code 1

With function code 1 the binary input and output signals of the modules are
transferredwithout the time. For module locations not in use the values 0
are transferred.
Function code 1, first master system
Function code 1, second master system
Response of the slave
Slave Code Bytes Event values module 1 ... Event values module 20 CRC
1 byte 1 byte 1 byte 4 bytes ... 4 bytes 2 bytes
Ereignisabfrage mit Code 3

When events are being checked via code 3, as many events are read out
of the buffer (a maximum of 31 events ∗ 8 bytes) as defined in the request
of the master system. As one event consists of 8 bytes, always four word
variables must be read together.
Error message during event check
Code Meaning
2 relative address or number of values do not correspond to the definition
Release of events for overwriting

Events which are read by a MODBUS master and their receiving confir-
med by the communication module are released for overwriting but not de-
leted.
If two master systems are active, the events are released for overwriting
after reading by one of the two masters.
47
Communication
Events released for overwriting are deleted if
– new events are written into the event buffer,

– with an overflow of the event buffer.
Overflow of the event buffer

If more events are received in the event buffer as there can be stored, then
the event “buffer overflow” is stored in the communication module. With
this event the MODBUS master is informed that an overflow has occured
and events have got lost.
11.1.6 Time Synchronization

Time and date of the communication module can be synchronized by a
master via MODBUS. Function code 70 is used for this purpose. With the
slave address 0 (broadcast) the master addresses all slaves; there is no
answer.
If only the time is to be transmitted, d must be set to 0; if only the date is

to be transmitted, ms has to be set to 255.
Function code 70
Slave Code Bytes Data CRC
1 byte 1 byte 1 byte 1 byte 1 byte 1 byte 1 byte 1 byte 1 byte 1 byte 1 byte 2 bytes
8 ms ds s min h d m a
0...99 0...9 0...59 0...59 0...23 0...31 1...12 0...99
The time can also be set via function code 6. For this purpose the telegram
with code 6 must contain the quantity of milliseconds passed since the last
full minute, i. e. the values are in the 0...59999 range. With the slave
address 0 (broadcast) the master addresses all slaves; there is no answer.
The address for the time synchronization is 2048.
Function code 6
Slave Code Address Data CRC
1 byte 1 byte 2 bytes 2 bytes 2 bytes
11.2 Communication via Profibus-DP

Profibus-DP is master-slave-system for the serial data transmission on a
bus. The construction of the hardware is the same as for the Modbus com-
munication.
The data transferred via Profibus-DP in the Planar4 system can be of ty-
pes WORD or BYTE.
Events can not be transferred.
Each Profibus-DP communication module in a Planar4 subrack is a slave

in a RS 485 network. The slave number is set via switches on the commu-
48
Communication
nication module (refer to data sheet).
The number of slaves on one bus segment is limited on to 31; via repea-
ters the system can be extended to four sements. Therefor the number of
adressable slaves is limited to 124 (refer to „communication via MODBUS
protocol“).
A redundant structure of the RS 485 bus system is not possible, because

in each subrack only one communication module can be build in and there
is only one interface on the module. Only the entire control can be struc-
tered in redundant.
11.3 Communication via Ethernet (OPC Server)

The OPC server is connected via a network to the HIMA Planar4 System.
For this network an Ethernet card is required for the PC, configured accor-
ding to TCP/IP. The OPC server can use the addresses 192.168.0.215 up
to 192.168.0.222.
The interface of the Ethernet card of the OPC server is connected via a
twisted-pair cable to a hub (connector RJ-45) where also the communica-
tion modules of all the Planar4 subracks are connected to.
Ethernet Network Structure
The communication modules of the subracks are connected with a twi-

sted-pair cable via the RJ-45 connector (10BaseT) to an Ethernet hub
which is linked to the Ethernet card of the HIMA OPC server. Each com-
munication module module has an own ID number in the range of 0...127;
the setting is made with switches on the module (cf. data sheet).
The IP address is calculated as follows:
IP-Address = ID number ∗ 2 + 1
So the results are always odd IP addresses. They are in the range of
192.168.2.3 up to 192.168.2.255.
In the configuration file of the HIMA OPC server the ID numbers must be
stated.
The detailed description of the communication is part of the “HIMA OPC

Server” manual.
49
Summary of the Symbols
12 Summary of the Symbols used in the Data Sheets

Symbol Function Commentary
AND gate 1-signal at all inputs produces 1-signal at the

output
OR gate 1-signal at one or more inputs produces 1-

signal at the output
Negation (Inverter) The output signal is inverted to the input signal
1-signal transfer For decoupling of outputs
Exclusive OR gate (antivalence) 1-signal at the output only if both input signals
are different
Equivalence 1-signal at the output only if both input signals

are equal (1 or 0)
Selection (m out of n gate) m or more of n inputs with 1-signal produce 1-

signal at the output
Monoflop Transition to 1-signal at the input produces a

short 1-signal at the output, independent on
the length of the input signal
Amplifier Amplifier with declaration of the output load of

max. 10 F
Power amplifier Amplifier with protection diode for swit-ching of

inductive loads and declaration of the output
load of max. 24 W
50
Inductive proximity switch Inductive sensor to DIN 19234 with declaration

of the polarity
Marking of an input 1-signal at open input; 0-signal is produced by

connection to L-
Marking of an input or output Input (output) not for a binary signal(no 1-

signal)
Declaration of the load At the input: load of 10 F

At the output: loadable with 10 F
Busbar Input or output suitable for busbars
Functional unit with signal conversion Dynamic signal processing by means of a

function frequency
Functional unit with galvanic isolation Galvanic isolation among input and output cir-
cuit
Functional unit with safe isolation Safe isolation to DIN VDE 0106
part 101/11.86
DC/DC converter Safe isolation of a DC voltage supply
Digital selection 2 decade preselection switch
Combined AND/OR gate Two dual AND gates are connected to a triple
OR gate
&
51
0-1 delay 1-signal at input E appears delayed at the out-

VESA = Delayed ON, at once OFF put A with the adjusted time t
1-0 delay After switching off 1-signal at input E, output A

SEVA = At once ON, delayed OFF extends the 1-signal with time t
0-1 and 1-0 delay ON delay with time t1 and OFF delay with time
VEVA = Delayed ON, delayed OFF t2
1-0 delay, adjustable in steps OFF delay, adjustable in 15 equal steps
Trigger stage If the input signal exceeds the operating point,

the output carries a signal; it is reset when the
input falls below the point
Limit stage Voltage or current values are limited to a cer-

tain value
Indicator light Indicator lights used on the modules are light

emitting diodes (LED)
Seven-segment display
Diagnose- und Kommunikationsmo- Recording and output of signals (simplified

dul (DCM) depiction with busbars) for diagnosis and error
message,connection for communication
52
Abbreviations used in the data sheets
AS Edition state
RC Requirement class
R Reset
S Set
SIL Safety Integrity Level
U Input for change of function mode
53
54
12 100 (9906)
12 100
4-fold Input Module 12 100
safety-related
with wire break and short circuit monitoring
The module is TÜV tested according to DIN V 19250 for RC 1...7 and ac-
cording to IEC 61508 for SIL 4.
12 100
RDY
ERR
Y1
LS1
LB1
Y2
LS2
LB2
Y3
LS3
LB3
Y4
LS4
LB4
Outputs k
The module evaluates the signal of a safety tested proximity switch and
indicates wire break and short circuit. If a mechanical contact is used in-
stead of a proximity switch, it must be equipped in the field with the appro-
piate resistors as shown above.
The outputs Y are safety-related. The outputs for line faults (LS and LB)
are not safety-related; they can be connected via a signal bus to a com-
mon central annunciation.
Inputs proximity switches according to DIN 19234,

safety tested, e. g. P+F ( ... SN),
or contacts with resistors 1 kΩ / 22 kΩ (0.25 W)
Switching time Y1...4 approx. 3 ms
Reset time Y1...4 approx. 3 ms
Operating data 24 V DC / 140 mA
Space requirement 3 U high, 4 SU
All rights reserved. The technology is subject to changes without notice: 1/4
HIMA Paul Hildebrandt GmbH + Co KG, Postfach 1261, 68777 Brühl
12 100 (9906)
Function table
Inputs Outputs
Y1...Y4 LS1...LS4 LB1...LB4
⊗ ⊗ ⊗
RA = 23 kΩ...2,9 kΩ
IE = 0,35...2,1 mA
⊗ ⊗
RA = 1,8 kΩ...0,9 kΩ
IE = 2,9...4,3 mA
RA < 600 Ω, IE > 5,1 mA (LS)

⊗ ⊗
⊗ ⊗
RA > 40 kΩ, IE < 0,2 mA (LB)
The current values for IE refer to the nominal open-circuit voltage 8.2
⊗ LED off LED on
All the functions on the module are monitored by a micro-controller.

A malfunction is indicated by ERR, the output d28 is on 1-signal and the
relay contact z26-d26 opens.
The output z28-b28 is provided for the connection to the communication
module, e. g. for data transfer to a process control system.
RDY (Ready) indicates the available power supply voltage (≥ 20 V).
Notes
When using safety tested proximity switches all statements and notes of
the manufacturer must be regarded.
For reasons of function and safety it is not permissible to connect the si-
gnal of one proximity switch onto two inputs.
For non-safety-related application it is also possible to use proximity

switches according to DIN 19234 with a resistor of 390 Ω (0,25 W).
2/4
12 100 (9906)
Communication via MODBUS

Reading of variables
Type BOOL: Function code 1
Type WORD: Function code 3
Events: Function codes 65, 66, 67
Rel. address Data type Value Meaning Rel. event no.

0 WORD 11 H Module type 12 100
1 BOOL 0 none
2 BOOL 1 Module removed
3 BOOL 1 Communication with module not o.k.
4 BOOL 1 Module in slot, communication o.k.
5 BOOL 1 Operating voltage too low, no RDY
6 BOOL 1 Module error, ERR
7 BOOL 1 Current in input circuits not o.k., LS, LB
8...40 BOOL 0 none
41 BOOL 1 1-signal at output z22 Y1 24
42 BOOL 1 1-signal at output d22 Y2 25
45...48 BOOL 0 none
Value: 0 always has the contrary meaning

H: hexadecimal value
absolute address: A = p ∗ 256 + rel. address
absolute event no.: E = (p - 1) ∗ 32 + rel. event no.
p = module location no. in the subrack
Reading of all variables

Function code 3, 84 words
since address 2000 H, 3000 H or 4000 H
Word 0 (16 bit) Word 1 (16 bit) Word 2 (16 bit) Word 3 (16 bit)
Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
Data Mod. type Mod. state none none none none none outputs
For a faultless data transfer all 84 words must be read. With that all the
variables of the modules of one subrack are transferred. For module loca-
tions not in use the values 0 are transferred.
3/4
12 100 (9906)
Communication via Profibus-DP

Relative addresses type WORD and type BYTE
WORD Bit BYTE Bit Value Meaning

0...7 0 0...7 11 H Module type 12 100
8 0 0 none
9 1 1 Module removed
10 2 1 Communication with module not o.k.
0 11 1 3 1 Module in slot, communication o.k.
12 4 1 Operating voltage too low, no RDY
13 5 1 Module error, ERR
14 6 1 Current in input circuits not o.k., LS, LB
15 7 0 none
1...2 2...5 0 none
0 0 1 1-signal at output z22 Y1
1 1 1 1-signal at output d22 Y2
3 2 6 2 1 1-signal at output z24 Y3
4...7 4...7 0 none
8...15 7 0...7 0 none

absolute address WORD: W = 4 ∗ (p - 1) + rel. address
absolute address BYTE: B = 8 ∗ (p - 1) + rel. address
4/4
13 110 (9906)
13 110
2-fold Input Module 13 110
(Ex)i, safety-related
with galvanic isolation,
with wire break and short circuit monitoring
EC-Type-Examination Certificate PTB 98 ATEX 2091 XThe module is

TÜV tested according to DIN V 19250 for RC 1...7 and according to IEC
61508 for SIL 4.
13 110
RDY
ERR
Y1
LS1
LB1
Y2
LS2
LB2
Outputs k
The module evaluates the signal of a safety tested proximity switch and
indicates wire break and short circuit. If a mechanical contact is used in-
stead of a proximity switch, it must be equipped in the field with the appro-
piate resistors as shown above.
The outputs Y are safety-related. The outputs for line faults (LS and LB)
are not safety-related; they can be connected via a signal bus to a com-
mon central annunciation.
Inputs proximity switches according to DIN 19234,

safety tested, e. g. P+F ( ... SN), or contacts
with resistors 1 kΩ / 22 kΩ (0,25 W)
Switching time Y1, Y2 approx. 2 ms
Reset time Y1, Y2 approx. 4 ms
13 110 (9906)
The switching amplifier has a safe isolation among the inputs and the po-
wer supply or the outputs, according to DIN VDE 0106 Part 101/11.86.
The clearence in air and the creepage distance are dimensioned for over-
voltage class II up to 300 V.
For (Ex)i application the female connector in the subrack must be equip-
ped with a coding pin on d6.The module is a corresponding electric instal-
lation which must be installed outside the hazardous area. The sensor
controlling the module may be mounted within the hazardous area.
Function table
Inputs Outputs
Y1, Y2 LS1, LS2 LB1, LB2
⊗ ⊗ ⊗
RA = 23 kΩ...2,9 kΩ
IE = 0,35...2,1 mA
⊗ ⊗
RA = 1,8 kΩ...0,9 kΩ
IE = 2,9...4,3 mA
RA < 600 Ω, IE > 5,1 mA (LS)

⊗ ⊗
⊗ ⊗
RA > 40 kΩ, IE < 0,2 mA (LB)
The current values for IE refer to the nominal open-circuit voltage 8.2 V
⊗ LED off LED on
All functions on the module are monitored by a micro-controller.

Notes
When using safety tested proximity switches all statements and notes of
the manufacturer must be regarded.
For reasons of function and safety it is not permissible to connect the si-
gnal of one proximity switch onto two inputs.
For non-safety-related application it is also possible to use proximity

switches according to DIN 19234 with a resistor of 390 Ω (0,25 W).
2/6
13 110 (9906)


1 BOOL 0 none
7 BOOL 1 Current in input circuits not o.k., LS, LB
8...40 BOOL 0 none
43...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
Data Mod. type Mod. state none none none none none Outputs
3/6
13 110 (9906)


0...7 0 0...7 11 H Module type 12 100
8 0 0 none
14 6 1 Current in input circuits not o.k., LS, LB
15 7 0 none
1...2 2...5 0 none
0...7 6 0...7 0 none
3 9 7 1 1 1-signal at output d24 Y2
10...15 2...7 0 none

4/6
13 110 (9906)
5/6
13 110 (9906)
6/6
22 100 (9906)
22 100
4-fold Output Module 22 100
safety-related
Outputs 25 V DC / 3 W
The module is TÜV tested according to DIN V 19250 for RC 1...7

and according to IEC 61508 for SIL 4.
d30
z30
d2
d4
d6
d8
z2
z4
z6
z8
1F 1F 1F 1F 1F 1F 1F 1F
22 100
EL+
RDY
ERR
DCM RDY
Y1
ERR
Y2
COM ERR Y3
+ -
Y4
L-
Y1 Y2 Y3 Y4
3W 3W 3W 3W 5F
b32
d32
b22
d22
b24
d24
d14
d16
d10
d18
d20
d12
b28
d28
b26
d26
z22
z24
z14
z10
z16
z18
z12
z20
z28
z26
z32
LL+
LL+
LL+
LL-
LL-
LL-
L-
L-
L-
Outputs k
With 1-signal at the AND inputs the output carries a quasi controlled volta-
ge of approx. 25 V which can be loaded up to 3 W. It is electrically isolated
from the supply voltage and able to control directly inductive loads. If the
module is used as a signal amplifier then the output pin z14 (z16, z18, z20)
must be connected to the L- reference pole.
To increase the availability the functions of two modules can be controlled

in parallel, and the ouputs decoupled by diodes z10 (d10, z12, d12) must
be connected in parallel.
All the functions on the module are monitored by a micro-controller.

Switching time approx. 3 ms

Reset time approx. 15 ms at nominal load
Operating data EL+ 24 V DC / 165 mA
Operating data LL+ 24 V DC / 0.7 A at nominal load
min. fusing: 1 A time-lag
22 100 (9906)


1 BOOL 0 none
7 BOOL 0 none
8 BOOL 1 no voltage LL+ for amplifiers
9 BOOL 1 1-signal at input z2 0
10 BOOL 1 1-signal at input d2 1
17...40 BOOL 0 none
45...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
Data Mod. type Mod. state none Inputs none none none Outputs
2/4
22 100 (9906)


0...7 0 0...7 21 H Module type 22 100
8 0 0 none
14 6 0 none
15 7 1 no voltage LL+ for amplifiers
0 0 1 1-signal at input z2
1 1 1 1-signal at input d2
1 4 2 4 1 1-signal at input z6
8...15 3 0...7 0 none
2 4...5 0 none
4...7 4...7 0 none
8...15 7 0...7 0 none

3/4
22 100 (9906)
For your notes
4/4
22 120 (9906)
22 120
Output Module 22 120
safety-related
output 25 V DC / 24 W

d30
z30
d2
d4
z2
z4
1F 1F 1F 1F
EL+ 22 120
RDY
ERR
YI YI
YO
DCM RDY
FLF
ERR
COM ERR
S + -
AUS
F OFF
S
EIN
ON
FLF F
L-
YO
24 W 5F 5F 5F
b28
d28
b26
d26
b22
d22
b24
d24
d16
d18
d10
z28
z26
b32
d32
z14
z22
z24
z16
z18
z32
LL+
LL+
LL+
k
LL-
LL-
LL-
Outputs F Delivery state 4 A time-lag

L-
L-
L-
With control at the inputs the output d16-d18 carries a quasi controlled
voltage of approx. 25 V which can be loaded up to 24 W nominal (at a no-
minal voltage of 24 V). It is electrically isolated from the supply voltage and
able to control directly inductive loads.
The switch S is used for a two-pole switching off of the output for purposes
of maintenance and repair. If only a single pole switching off is required,
the pin d16 can be connected with the pin z16.
The delivery state of the fuse F is 4 A time-lag. Normally the fuse does not
blow in case of a short circuit as the module output is short-circuit-proof.
The fuse is designed for the use as the specified back-up fuse for (Ex)d
type valves (flameproof enclosure) in the Ex area 1. The corresponding
value must be taken from the test certificate of the used solenoid valve.

Reset time (z18/d18) approx. 12 ms at nominal load
Reset time (d10) approx. 7 ms
Operating data LL+ 24 V DC / 1.4 A at nominal load,
22 120 (9906)
Opening of the switch contacts S or fuse tripping is indicated by FLF. The

output z14 is not safety-related; it is suitable for connection to a busbar.

Notes
The output d10 is provided for the design of a latching circuit (via input d4).
For safety reasons it may not be used for wired-OR connections.
To increase the availability, two modules can be controlled in parallel, and

the ouputs decoupled by diodes (z18) must be connected in parallel.
The module is available as 22 121 type with the same function but an out-
put voltage of 60 V DC.
2/4
22 120 (9906)


1 BOOL 0 none
7 BOOL 1 Error in the output circuit, FLF
13...40 BOOL 0 none
41 BOOL 1 1-signal at output d10 YI 24
42 BOOL 1 1-signal at output d18 YO 25
43...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
22 120 (9906)


0...7 0 0...7 22 H Module type 22 120
8 0 0 none
14 6 1 Error in the output circuit, FLF
4...7 4...7 0 none
8...15 3 0...7 0 none
2 4...5 0 none
0 0 1 1-signal at output d10 YI
3 1 6 1 1 1-signal at output d18 YO
2...7 2...7 0 none
8...15 7 0...7 0 none

4/4
22 121 (9906)
22 121
Output Module 22 121
safety-related
output 60 V DC / 24 W
d30
z30
d2
d4
z2
z4
1F 1F 1F 1F
EL+
22 121
RDY
ERR
YI YI
YO
DCM RDY FLF
ERR
COM ERR
S + - AUS
OFF
F
S
EIN
ON
FLF F
L-
YO
24 W 5F 5F 5F
b28
d28
b26
d26
b22
d22
b24
d24
d16
d18
d10
z28
z26
b32
d32
z14
z22
z24
z16
z18
z32
LL+
LL+
LL+
LL-
LL-
LL-
k F Delivery state 4 A time-lag

L-
L-
L-
Outputs
With control at the inputs the output d16-d18 carries a quasi controlled
voltage of approx. 60 V which can be loaded up to 24 W nominal (at a no-
minal voltage of 60 V). It is electrically isolated from the supply voltage and
able to control directly inductive loads.
The switch S is used for a two-pole switching off of the output for purposes
of maintenance and repair. If only a single pole switching off is required,
the pin d16 can be connected with the pin z16.
The delivery state of the fuse F is 4 A time-lag. Normally the fuse does not
blow in case of a short circuit as the module output is short-circuit-proof.
The fuse is designed for the use as the specified back-up fuse for (Ex)d
type valves (flameproof enclosure) in the Ex area 1. The corresponding
value must be taken from the test certificate of the used solenoid valve.

Reset time (z18/d18) approx. 12 ms at nominal load
Reset time (d10) approx. 7 ms
Operating data LL+ 24 V DC / 1.4 A at nominal load,
22 121 (9906)
Opening of the switch contacts S or fuse tripping is indicated by FLF. The

output z14 is not safety-related; it is suitable for connection to a busbar.

Notes
The output d10 is provided for the design of a latching circuit (via input d4).
For safety reasons it may not be used for wired-OR connections.
To increase the availability, two modules can be controlled in parallel, and

the ouputs decoupled by diodes (z18) must be connected in parallel.
For safety reasons these modules should be placed in a separate subfra-

me with an entire protection cover at the rear or with covering of the pins
with shrink sleeves.
The module is available as 22 120 type with the same function but an out-
put voltage of 25 V DC.
2/4
22 121 (9906)


1 BOOL 0 none
7 BOOL 1 Error in the output circuit, FLF
13...40 BOOL 0 none
41 BOOL 1 1-signal at output d10 YI 24
42 BOOL 1 1-signal at output d18 YO 25
43...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
22 121 (9906)


0...7 0 0...7 23 H Module type 22 121
8 0 0 none
14 6 1 Error in the output circuit, FLF
4...7 4...7 0 none
8...15 3 0...7 0 none
2 4...5 0 none
0 0 1 1-signal at output d10 YI
3 1 6 1 1 1-signal at output d18 YO
2...7 2...7 0 none
8...15 7 0...7 0 none

4/4
32 100 (9906)
32 100
2-fold Relay Amplifier 32 100
safety-related
Switching voltage 24 V DC / 24 V AC

d30
d16
d18
d20
d22
z30
z16
z18
z20
z22
1F 1F 1F 1F 1F 1F 1F 1F
32 100
EL+
RDY
ERR
OC1
FF1
DCM RDY OC2
FF2
ERR
COM ERR
+ -
F1 F2
OC1 OC2
F1
F2
L-
FF1 FF2
2F 5F 2F 5F b28 5F
d28
b26
d26
d24
d10
d14
b32
d32
z28
z26
z24
z14
z32
d4
L1 d2
L1 d8
L2 z2
L2 z8
(N)
(N)
F1, F2 Delivery state 4 A time-lag
The module is equipped with diverse relays according to the standards

DIN V VDE 0801 A1, DIN VDE 0116 and EN 298. The limitation of the con-
tact current to 60% of the at most possible value (according to DIN VDE
0116) is achieved by the fusing and keeping the data sheet values. Thus
the amplifier can be used for safety shutdowns, e. g. to cut off the entire
fuel supply for incinerator plants (DIN VDE 0116/10.89, item 8.7.2).
Output 1 floating NO contact each (sealed)

Contact data: cf. reverse
Switching time (contact) approx. 10 ms
Reset time (contact) approx. 12 ms
Switching time (signal) approx. 3 ms
Reset time (signal) approx. 8 ms
32 100 (9906)
The relay amplifier has a safe isolation of the inputs resp. the power supply
from the output contacts, according to DIN VDE 0106 Part 101/11.86 resp.
DIN VDE 0160/05.88. The clearence in air and the creepage distance are
dimensioned for overvoltage class III up to 300 V.
The output contacts are isolated one from each other up to 250 V accor-
ding to VDE 0110 part 1 (01.89), overvoltage class III.
Closing of the relay contacts d2-d4 (d8-d10) is indicated by OC1 (OC2). A

tripped fuse F1 (F2) is signalized by the output z14 (d14) and with the LED
FF1 (FF2). The outputs z14 and d14 are not safety-related; they are sui-
table for connection to a busbar.
Relay contact
Contact material AgNi, gold-plated

Switching current ≤ 4 A, ≥ 10 mA
Inrush peak current ≤ 12 A for 1 s (non-periodic)
Fusing 4 A time-lag (delivery state)
Switching AC ≤ 120 VA, cos ϕ > 0.5
capacity DC ≤ 120 W, non-inductive load
Bounce time approx. 1.5 ms
Switching frequency ≤ 10 cycles/s
Life
mechanical > 107 cycles
electrical > 2.5 x 105 cycles
at resistive load and ≤ 0.1 cycles/s
All functions on the module including the output contacts with the fuses are
monitored by a micro-controller.
Notes
For the monitoring of the output circuit the reference pole (L2/N) of the
switching voltage must be connected to z2 (z8).
The output z24 (d24) is provided for the design of a latching circuit via in-
put d18 (d22). For safety reasons it may not be used for wired-OR connec-
tions.
The module is available as 32 101, 32 102 or 32 103 type with the same
functions but other switching voltages.
2/4
32 100 (9906)


1 BOOL 0 none
7 BOOL 1 Fuse faulty, FF1, FF2
8 BOOL 1 no switching voltage at the contact circuit
17...40 BOOL 0 none
41 BOOL 1 1-signal at output z24 24
42 BOOL 1 1-signal at output d4 25
45...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
32 100 (9906)


0...7 0 0...7 31 H Module type 32 100
8 0 0 none
14 6 1 Fuse faulty, FF1, FF2
15 7 1 no switching voltage at the contact circuit
8...15 3 0...7 0 none
2 4...5 0 none
0 0 1 1-signal at output z24
1 1 1 1-signal at output d4
3 2 6 2 1 1-signal at output d24
4...7 4...7 0 none
8...15 7 0...7 0 none

4/4
32 101 (9906)
32 101
safety-related
Switching voltage 48/60 V DC / 60 V AC

d30
d16
d18
d20
d22
z30
z16
z18
z20
z22
1F 1F 1F 1F 1F 1F 1F 1F
32 101
EL+
RDY
ERR
OC1
FF1
DCM RDY OC2
FF2
ERR
COM ERR
+ -
F1 F2
OC1 OC2
F1
F2
L-
FF1 FF2
2F 5F 2F 5F b28 5F
d28
b26
d26
d24
d10
d14
b32
d32
z28
z26
z24
z14
z32
d4
L1 d2
L1 d8
L2 z2
L2 z8
(N)
(N)

With switching voltages of 60 V for safety reasons these modules should

be placed in a separate subframe with an entire protection cover at the
rear or with covering of the pins with shrink sleeves.

32 101 (9906)

Relay contact

Switching voltage 48/60 V DC / 60 V AC
Life
Notes
tions.
2/4
32 101 (9906)


1 BOOL 0 none
17...40 BOOL 0 none
45...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
32 101 (9906)


0...7 0 0...7 32 H Module type 32 101
8 0 0 none
8...15 3 0...7 0 none
2 4...5 0 none
4...7 4...7 0 none
8...15 7 0...7 0 none

4/4
32 102 (9906)
32 102
safety-related

d30
d16
d18
d20
d22
z30
z16
z18
z20
z22
1F 1F 1F 1F 1F 1F 1F 1F
32 102
EL+
RDY
ERR
OC1
FF1
DCM RDY OC2
FF2
ERR
COM ERR
+ -
F1 F2
OC1 OC2 F1
F2
L-
FF1 FF2
2F 5F 2F 5F b28 5F
d28
b26
d26
d24
d10
d14
b32
d32
z28
z26
z24
z14
z32
d4
L1 d2
L1 d8
L2 z2
L2 z8
(N)
(N)



32 102 (9906)

Relay contact

Life
Notes
tions.
2/4
32 102 (9906)


1 BOOL 0 none
17...40 BOOL 0 none
45...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
32 102 (9906)


0...7 0 0...7 33 H Module type 32 102
8 0 0 none
8...15 3 0...7 0 none
2 4...5 0 none
4...7 4...7 0 none
8...15 7 0...7 0 none

4/4
32 103 (9906)
32 103
safety-related

d30
d16
d18
d20
d22
z30
z16
z18
z20
z22
1F 1F 1F 1F 1F 1F 1F 1F
32 103
EL+
RDY
ERR
OC1
FF1
DCM RDY OC2
FF2
ERR
COM ERR
+ -
F1 F2
OC1 OC2
F1
F2
L-
FF1 FF2
2F 5F 2F 5F b28 5F
d28
b26
d26
d24
d10
d14
b32
d32
z28
z26
z24
z14
z32
d4
L1 d2
L1 d8
L2 z2
L2 z8
(N)
(N)



32 103 (9906)

Relay contact

Life
Notes
tions.
2/4
32 103 (9906)


1 BOOL 0 none
17...40 BOOL 0 none
45...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
32 103 (9906)


0...7 0 0...7 34 H Module type 32 103
8 0 0 none
8...15 3 0...7 0 none
2 4...5 0 none
4...7 4...7 0 none
8...15 7 0...7 0 none

4/4
32 110 (9906)
32 110
safety-related

32 110
d22
d24
d30
z30
z22
z24
RDY
1F 1F 1F 1F ERR
EL+
K1
DCM RDY K2
K3
ERR K4
COM ERR
+ - F1
F2
F3
L-
5F F4
b28
d28
b26
d26
b32
d32
d10
d14
z32
z28
z26
z10
z14
d2
d6
z2
z6
F1... F4 Delivery state 4 A time-lag
The relay amplifier has a safe isolation of the inputs resp. the power sup-
ply from the output contacts, according to DIN VDE 0106 Part 101/11.86
resp. DIN VDE 0160/05.88. The clearence in air and the creepage di-
stance are dimensioned for overvoltage class III up to 300 V.
The outputs are suitable for switching of safety circuits according to DIN
VDE 0116.
Higher requirement classes can be reached by contact outputs connected

in series.

Reset time approx. 18 ms
32 110 (9906)
Relay contact

Switching voltage ≤ 250 V DC / AC, ≥ 1 mV
(≤ 60 V with special protection)
Inrush peak current ≤ 12 A for 1 s
(non-periodic)
capacity DC up to 30 V: ≤ 60 W,
up to 250 V: ≤ 40 W,
non-inductive load
Life
All functions on the module except the output contacts with the fuses are
Note
If contact switching voltages > 60 V are used, for safety reasons these mo-
dules should be placed in a separate subframe with an entire protection
cover at the rear or with covering of the pins with shrink sleeves.
2/4
32 110 (9906)


1 BOOL 0 none
7...8 BOOL 0 none
13...40 BOOL 0 none
41 BOOL 1 Relay 1 energized K1 24
45...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
32 110 (9906)


0...7 0 0...7 35 H Module type 32 110
8 0 0 none
14 6 0 none
15 7 0 none
4...7 4...7 0 none
8...15 3 0...7 0 none
2 4...5 0 none
0 0 1 Relay 1 energized K1
3 2 6 2 1 Relay 3 energized K3
4...7 4...7 0 none
8...15 7 0...7 0 none

4/4
42 100 (9906)
42 100
4-fold AND Element 42 100
safety-related
with five inputs each

d30
z30
42 100
RDY
EL+ ERR
Y1
Y2
DCM RDY Y3
Y4
ERR
COM ERR
+ -
L-
5F
b28
d28
b26
d26
b32
d32
z28
z26
z32
Outputs k
The module realizes four AND functions with four inputs each; additional
OR gates enable the design of latching circuits.


42 100 (9906)


1 BOOL 0 none
7...8 BOOL 0 none
29...40 BOOL 0 none
45...48 BOOL 0 none

2/4
42 100 (9906)

Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
Data Mod. type Mod. state Inputs Inputs none Inputs none Outputs
3/4
42 100 (9906)


0...7 0 0...7 41 H Module type 42 100
8 0 0 none
14 6 0 none
15 7 0 none
3 2 3 1 1-signal at input d4
4..7 4...7 0 none
8...15 5 0...7 0 none
3 2 6 2 1 1-signal at output z24 Y3
4...7 4...7 0 none
8...15 7 0...7 0 none

4/4
42 110 (9906)
42 110
8-fold AND Element 42 110
safety-related
with two inputs each

d30
d10
d12
d14
d16
z30
z10
z12
z14
z16
d2
d4
d6
d8
z2
z4
z6
z8
1F 1F 1F 1F 1F 1F 1F 1F 1F 1F 1F 1F 1F 1F 1F 1F 42 110
EL+ RDY
ERR
DCM RDY Y1
Y2
ERR Y3
Y4
COM ERR
-
Y5
+
Y6
Y7
Y8
Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8
L-
10 F 10 F 10 F 10 F 10 F 10 F 10 F 10 F 5F
b28
d28
b26
d26
z28
z26
d18
d20
d22
d24
b32
d32
z18
z20
z22
z24
z32
Outputs k
The module realizes eight AND functions with two inputs each.


42 110 (9906)


1 BOOL 0 none
7...8 BOOL 0 none
25...40 BOOL 0 none

2/4
42 110 (9906)

Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
Data Mod. type Mod. state Inputs Inputs none none none Outputs
3/4
42 110 (9906)


0...7 0 0...7 42 H Module type 42 110
8 0 0 none
14 6 0 none
15 7 0 none
2 4...5 0 none
3 6 3 1 1-signal at output d20 Y4
3 4 4 1 1-signal at output z22 Y5
8...15 7 0...7 0 none

4/4
42 200 (9906)
42 200
Element Combination 42 200
safety-related
4 AND elements, 2 OR elements, 1 blocking element

d30
d12
d14
d16
z30
z12
z14
z16
d2
d4
d6
z2
z4
z6
42 200
1F 1F 1F 1F 1F 1F 1F 1F
RDY
EL+ ERR
Y1
Y2
DCM RDY
Y3
ERR Y4
COM ERR
+ -
Y7
Y7
L- Y1 Y2 Y3 Y7 Y7
10 F 10 F 10 F 10 F 10 F 5F
d18
d24
b28
d28
b26
d26
b32
d32
d22
z18
z20
z22
z24
z28
z26
z32
Outputs k
The blocking element guarantees that there never will be 1-signal at both
the direct and the inverted output at the same time. To ensure this also wi-
thin a logic, the direct signal must be taken only from the output of the blok-
king element:
not
correct
permissible
When controlling and resetting the input, the 1-signals at the direct and the
inverted output do not overlap.
Switching times, cf. reverse

Reset times
Fuse 0.375 A
AND element:
Blocking element:
42 200 (9906)
Switching time Y7 approx. 15 ms

Y7 approx. 4 ms
Reset time Y7 approx. 3 ms
Y7 approx. 10 ms
Diodes:
Reverse voltage ≤ 1000 V
Reverse current ≤ 50 µA
Reverse recovery time typ. 30 µs
Peak value of the
conducting state voltage3 x 1 V
Nominal current
in conducting state ≤ 200 mA

2/6
42 200 (9906)


1 BOOL 0 none
7...8 BOOL 0 none
25...40 BOOL 0 none

3/6
42 200 (9906)

Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
4/6
42 200 (9906)


0...7 0 0...7 46 H Module type 42 200
8 0 0 none
14 6 0 none
15 7 0 none
2 4...5 0 none
3 4 4 1 1-signal at output z22
8...15 7 0...7 0 none

5/6
42 200 (9906)
For your notes
6/6
42 300 (9906)
42 300
8-fold OR Element 42 300
safety-related
with two inputs each

d30
d10
d12
d14
d16
z30
z10
z12
z14
z16
d2
d4
d6
d8
z2
z4
z6
z8
42 300
RDY
ERR
EL+
DCM RDY
ERR
COM ERR
+ -
L-
5F
b28
d28
b26
d26
z28
z26
d18
d20
d22
d24
b32
d32
z18
z20
z22
z24
z32
The module realizes eight OR functions with two inputs each.

Diodes:
Reverse voltage ≤ 1000 V
Reverse current ≤ 50 µA
Reverse recovery time typ. 30 ms
Peak value of the
conducting state voltage3 x 1 V
Nominal current
in conducting state ≤ 200 mA
Fuse 0.375 A time-lag
Switching time non-delayed
42 300 (9906)


1 BOOL 0 none
7...8 BOOL 0 none
25...40 BOOL 0 none

2/4
42 300 (9906)

Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
42 300 (9906)


0...7 0 0...7 43 H Module type 42 300
8 0 0 none
14 6 0 none
15 7 0 none
2 4...5 0 none
3 6 3 1 1-signal at output d20
8...15 7 0...7 0 none

4/4
42 400 (9906)
42 400
4-fold Blocking Element 42 400
safety-related

d30
z30
d2
d4
d6
d8
42 400
1F 1F 1F 1F
RDY
EL+
ERR
Y1
DCM RDY
Y1
ERR Y2
Y2
COM ERR
Y3
+ -
Y3
Y4
Y4
Y1 Y1 Y2 Y2 Y3 Y3 Y4 Y4
L-
10 F 10 F 10 F 10 F 10 F 10 F 10 F 10 F 5F
d18
d20
d22
d24
b28
d28
b26
d26
b32
d32
z28
z26
z18
z20
z22
z24
z32
Outputs k
The blocking element guarantees that there never will be 1-signal at both
the direct and the inverted output at the same time. To ensure this also wi-
thin a logic, the direct signal must be taken only from the output of the blok-
king element:
not
correct permissible
When controlling and resetting the input, the 1-signals at the direct and the
inverted output do not overlap.

Switching time direct output approx. 20 ms

inverted output approx. 3 ms
Reset time direct output approx. 3 ms
inverted output approx. 15ms
42 400 (9906)


1 BOOL 0 none
7...8 BOOL 0 none
13...40 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
2/4
42 400 (9906)


0...7 0 0...7 44 H Module type 42 400
8 0 0 none
14 6 0 none
15 7 0 none
1 2 2 2 1 1-signal at input d6
4...7 4...7 0 none
8...15 3 0...7 0 none
2 4...5 0 none
8...15 7 0...7 0 none

3/4
42 400 (9906)
For your notes
4/4
42 500 (9906)
42 500
4-fold Selection Element 42 500
safety-related
2 out of 3 selection
42 500
RDY
ERR
Y1
DF1
Y2
DF2
Y3
DF3
Y4
DF4
Outputs k
If at least 2 of 3 inputs z2, d2, d4 (z6, d6, z8 etc.) are set to 1-signal, then
the output z22 (d22 etc.) is also on 1-signal. The outputs are decoupled by
diodes; they can be connected in parallel for OR functions (wired OR).
The switch DZ on the PCB of the module enables the setting of the tole-
rance time for discrepancies of the signals in 15 steps. If the set time is
exceeded, then the output z18 (d18 etc.) is on 1-signal and the LED DF1
(DF2 etc.) is on. The outputs DF are not safety-related; they can be con-
nected via a signal bus to a common annunciation.

Switching time (Y1...Y4) approx. 2 ms

Reset time (Y1...Y4) approx. 5 ms
Switching time (DF1...DF4) 3 ms (at DZ = 0)...15 s, in 15 steps
Reset time (DF1...DF4) approx. 3 ms
42 500 (9906)


1 BOOL 0 none
7...8 BOOL 0 none
21...40 BOOL 0 none
42 BOOL 1 1-signal at output z18 DF1 25
44 BOOL 1 1-signal at output d18 DF2 27
46 BOOL 1 1-signal at output z20 DF3 29
48 BOOL 1 1-signal at output d20 DF4 31

2/4
42 500 (9906)

Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
42 500 (9906)


0...7 0 0...7 45 H Module type 42 500
8 0 0 none
14 6 0 none
15 7 0 none
3 2 3 1 1-signal at input z6
1 6 6 1 1-signal at input z10
12...15 4...7 0 none
2 4...5 0 none
1 1 1 1-signal at output z18 DF1
3 6 3 1 1-signal at output d18 DF2
5 5 1 1-signal at output z20 DF3
7 7 1 1-signal at output d20 DF4
8...15 7 0...7 0 keine

4/4
52 100 (9908)
52 100
Time Delay Element 52 100
safety-related

52 100
RDY
ERR
Y
Y
TR
TIME
ACK
Outputs k
Selection Time range Resolution
ZF1 0,1...9.9 s 0.1 s

ZF2 1...99 s 1s
ZF3 10...990 s 10 s
ZF4 60...5 940 s 60 s
ZF 5 600...59 400 s 600 s
Time accuracy < 0.1 % of defined value

Reference error -10...+90 ms
The 1-signals at the outputs Y and Y do not overlap (gap of approx. 20

ms).
Switching time Y approx. 45 ms

Y approx. 25 ms
Reset time Y approx. 20 ms
Y approx. 40 ms
Space requirement 3 HE, 4 TE
52 100 (9908)
The safety-related time delay element is a two channel safety-related pro-

cessor system. Each processor sys-tem operates the preset time
functions and proceeds self-tests and monitoring functions. The module is
initialized after switching on the power supply or by pressing the pushbut-
ton ACK (after a disturbance). After the initialization the safety-related out-
puts Y and Y are activated.
The time setting is made by the connection of EL+ to only one of the time
factor inputs ZF1...ZF5, and the setting of the two-decade selector switch
on the front plate. The delay time or pulse time td is calculated by means
of the formula:
tv = resolution x decade selector switch value
During operation changes of the changeover input (U) at pulse functions,

the function inputs (F1, F2) and the time factor inputs (ZF1...ZF5) are not
permissible. A change of the decade switch value (LED TR flashing) re-
quires striking the pushbutton ACK within 60s or the selection of the pre-
vious value; otherwise the module will turn to the error state. A time
change is activated only with a new triggering signal.
In the case of a disturbance or a fault (internal error or component fault)

both safety-related outputs Y and Y are reset to 0-signal (no output signal),
and the fault output ERR is set to 1-signal. During a time in operation the
time of the function “0-1 delay” can turn to an infinite value, the time of the
function “1-0 delay” and pulse functions can turn to zero.
Functions
The functions can be achieved with the following connections (control si-
gnal at input E):
2/6
52 100 (9908)
Function of the LEDs

Y, Y (yellow) Indication of the outputs Y and Y
TR (yellow) Time counter running (steady on),
initialization (steady on),
time change (flashing)

This is also made for functions not recorded by the safety-related part, as
there may occur failures into the safe direction (e. g. component fault at
the control input E).
Remarks
In the 1-0 delay (SEVA) a running time can be set to zero (= delay time
over) by means of a short-time interruption of the EL+ at input d4 (e. g. with
a pushbutton):
Notes
For protection of the adjusted time the module must be installed in a way
that an unauthorized change of the adjusted time is impossible.
The maximum fault detection time and reaction time of 75 ms must be ad-
ded to the selected delay time to get the safety time.
Restrictions
0-1 delay VESA (delayed on, immediately off):
Permissible only in applications, where the adjusted time may increase
but not decrease.
1-0 delay SEVA (immediately on, delayed off):

Permissible only in applications, where the adjusted time may decrease
but not increase.
0-1 and 1-0 delay VEVA (delayed on, delayed off):

Permissible only in applications, where the adjusted time may increase
but not decrease (at switching on);
permissible only in applications, where the adjusted time may decrease
but not increase (at switching off).
Pulse (with input signal change 0-1):

Permissible only in applications, where the adjusted time may decrease
but not increase.
3/6
52 100 (9908)


0 WORD E1 H Module type 52 100
1 BOOL 0 none
7...8 BOOL 0 none
9 BOOL 1 1-signal at control input d2 0
10 BOOL 1 1-signal at switch-over input d4 1
11...24 BOOL 0 none
25 BOOL 0... Residual delay time in seconds
65 535
26 BOOL 1 1-signal at output d22 Y 24
27 BOOL 1 1-signal at output d24 Y 25
28...33 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 25 33 . . . . . . 26
Data Mod. type Mod. state none Inputs Residual delay time in s none Outputs
4/6
52 100 (9908)


0...7 0 0...7 E1 H Module type 52 100
8 0 0 none
14 6 0 none
15 7 0 none
0 0 1 1-signal at control input d2
1 1 2 1 1 1-signal at switch-over input d4
2...7 2...7 0 none
8...15 3 0...7 0 none
2 8...15 4 0...7 0...127 Residual delay time (high byte) in seconds
0...7 5 0...7 0...127 Residual delay time (low byte) in seconds
0 0 1 1-signal at output d22 Y
3 1 6 1 1 1-signal at output d24 Y
2...7 2...7 0 none
8...15 7 0...7 0 none

5/6
52 100 (9908)
For your notes
6/6
52 110 (9906)
52 110
4-fold Time Delay Element 52 110
safety-related
delay-off (SEVA), time range 1...15 s

d30
z30
52 110
EL+ RDY
ERR
Y1
0 0 0 0
DCM RDY Y2
t 15 s t 15 s t 15 s t 15 s Y3
ERR Y4
F0 1
COM ERR
B C DE
23
T1
4 5
+ - 8 9A
67
F0 1
B C DE
23
T2
4 5
67
8 9A
F0 1
B C DE
23
T3
45
67
8 9A
L- F0 1
B C DE
23
T4
4 5
5F 8 9A
67
b28
d28
b26
d26
b32
d32
z28
z26
z32
Outputs k
Selector switch 0 1 2 ... 9 A B C D E F
Delay-off time (seconds) 0 1 2 ... 9 10 11 12 13 14 15
Time accuracy 7%
The delay times to transfer a signal change 1-0 from the input to the output
can be set in 15 steps by separated selector switches ont the front plate.
Switching time 120...50 ms,

depending on 1-signal
Setting time ≥ 500 ms (cf. reverse)
52 110 (9906)

relay contact z26-d26 opens. This also occurs if the time deviates ± 30%
or more from the defined value.
Notes
Before triggering the time delay (by switching off the input signal) the input
signal must be present for at least 500 ms. If this setting time is shorter,
possibly the full delay time at the output cannot be reached.
The delay-off function is defined to be the safety function. In case of an

error the delay-off time of the function signal can be up to 90 seconds.
2/4
52 110 (9906)


1 BOOL 0 none
7...8 BOOL 0 none
13...40 BOOL 0 none
45...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
52 110 (9906)


0...7 0 0...7 51 H Module type 52 110
8 0 0 none
14 6 0 none
15 7 0 none
1 2 2 2 1 1-signal at input d6
4...7 4...7 0 none
8...15 3 0...7 0 none
2 4...5 0 none
4...7 4...7 0 none
8...15 7 0...7 0 none

4/4
62 100 (9908)
62 100
2-fold analogue Limit Monitor 62 100
safety-related
Input 0...22 mA / 0...5.5 V without line diagnosis
or 4...22 mA / 1...5.5 V with line diagnosis
2 outputs 100 mA each with parameterizable line diagnosis
The module is TÜV tested according to DIN V 19250 for RC 1...6 and
according to IEC 61508 for SIL 3.
d30
d14
d10
d12
z30
z10
z12
z14
*z2
d6
d8
* Connection not required

z6
z8
62 100
250 Ω 250 Ω
EL+ - + - +
MUX
A A
D D
Value Menue ACK
Processor Unit 1 1oo2 System Processor Unit 2
Display 1 Display 2 DCM RDY
1 2 1 2
LS LB LS LB ERR
Channel 1 Alarm Channel 2 COM ERR

+ -
Ch 1 Ch 2
T 1 T 2 T 1 T 2
L- - + - + - + - +
100 mA 100 mA 100 mA 100 mA 5F

b28
d28
b26
d26
z28
z26
d18
d20
d22
d24
b32
d32
b30
z18
z20
z16
z22
z24
z32
*d2
*d4
*z4
Outputs k
Analog section
Input voltage 0...5.5 V
Input current 0...22 mA (250 Ω Shunt)
Measuring range according to NE 43 (I > 3.6 mA, I < 21 mA)
Input resistance ≥ 100 kΩ
Basis error ≤ 0.25 % of upper value (+25 °C)
Operating error ≤ 0.4 % of upper value
at -25...+70 °C
Resolution 12 Bit (upp. value incl. overflow)
Filter constant 10 ms
Digital section
Switching time < 250 ms
Output:
Current limit 0.11 A ± 10 %
Int. voltage drop 2.5 V at max. load
Min. load 12 kΩ (no lamp load)
Max. inductivity 1H
Safety time 250 ms

Operating data 24 V DC / 170 mA, plus load
62 100 (9908)
The safety-related limit monitor 62 100 for analogue circuits is a 4 spacing

units wide module suitable for a 19-inches subrack, 3 units high. The mo-
dule is equipped with a double processor system. It has two voltage inputs
0...5.5 V electrically isolated from the outputs. The limit value outputs are
switched when reaching the adjustable limit plus hysteresis values. If the
input voltage leaves the admissible standard range, this is indicated optio-
nally by the common ’Alarm’ signal output or by an error signal and swit-
ching-off of the module.
In applications together with safety-related transmitters either two limit va-

lues can be adjusted for two independent analog circuits. In applications
with redundant operating transmitters only two limit values can be adju-
sted per module. As in practice there are quite often no safety-related
transmitters for requirement class 6 available, two transmitters are provi-
ded at the same measuring point in this case. Their analog values are
compared to differences in the preset values and time. Exceeding the va-
lue difference is indicated by the common alarm signal output.
Also the rate-of-change (the gradient) of an analog value can be recorded

over an adjustable time basis and allocated to limit values.
The short-circuit proof outputs can be preset with the following parame-
ters: limit value or rate of change (gradient), hysteresis, triggered direc-
tion, and optionally line diagnosis (monitoring of the output circuit lines for
short-circuit and wire break). The outputs of safety-related limit monitors
can be connected in parallel for increasing the availability.
The digitized analog values of both channels are displayed as a percenta-

ge value with a resolution of 0.1 % via an LCD on the front panel. The 1-
signal of the outputs is indicated by an alighted frame around the corre-
sponding icon. A line break or a short circuit in the output circuits is indi-
cated by flashing icons.
The module is programmed via five pushbuttons and the LCDs on the front
panel. An additional device or a PC with a special software program is not
required.
For safety reasons it is not possible to change parameters during operati-

on. During operation, however, the set parameters can be selected and
displayed using the pushbuttons on the front panel.
Used as a stand-alone system the module can operate without any redu-
cing of the immunity also in a plastic case.
The notes on page 7 of this data sheet for safety-related operation and use
as well as the notes in the System Manual of the Planar4 System must be
regarded.
2/20
62 100 (9908)

Examples of displays
62 100 62 100 62 100
LED ERR flashing

Output 1:
H-Signal Limit value
channel 1, output 1
Current value
Output 2:
H-Signal
Current value
Operating Mode: RUN RUN Parameterization
LB
Wire break, number of the faulty channel is
flashing
LS
Short circuit, number of the faulty channel is
flashing
3/20
62 100 (9908)
Parameter Range Resolution
Limit value
0...20 mA / 0...5 V 0.0...110.0 % * 0.1 %
4...20 mA / 1...5 V 0.0...112.5 % * 0.1 %
Hysteresis 0.5/1...100 % 1%
Default value 0.5 %
*at max. 22 mA / 5.5 V
If the analog input value is outside the standard range (< 3.6 mA / 0.9 V,
> 21 mA / 5.25 V according to NE 43), the output z16 (Alarm) is set on 1-
signal. Optionally the module can activate the ERR signals (output d28, re-
lay contact, LED) and switch off all the limit value outputs.In the 4...20 mA
/ 1...5 V operating mode for input values <4 mA / 1 V internally the value
0 % is used for proceeding.
Actuating direction L (Low)

The limit value output is deenergized if the input value is lower than the
limit, and is energized again if the input value is higher than the limit plus
value of the hysteresis.
Actuating direction H (High)

The limit value output is deenergized if the input value is higher than the
limit, and is energized again if the input value is lower than the limit minus
value of the hysteresis.
Line diagnosis of the limit value outputs

can be defined, display with current failureThe outputs are safety-related.
If safety-related modules are controlled by them, no line monitoring must
be defined for the outputs.
Non-safety-related transmitters/sensors for use in safety-related ap-

plications
The limit monitor performs also the parallel operation of two non safety-
related transmitters/sensors in a 1oo2 voting operation circuit (AND) in
safety-related applications up to RC 6 / SIL 3. For all four outputs of the
module a limit value can be set and additionally the discrepancies for va-
lues and time period can be adjusted.
As limit value the minimum, average or maximum value of both sensors

can be selected.
Limit value 0...100.0 % 0.1 %
Hysteresis 0.5/1...100 % 1%
Default value 0.5 %
Value discrepancy 1.0...90.0 % 0.5 %
Time discrepancy 0.1...199.9 s 0.1 s

1...1999 s 1s
When exceeding the value discrepancy the output z16 (Alarm) is set to 1-
signal during the discrepancy period; after this period all the appertaining
limit value outputs are switched off.
4/20
62 100 (9908)
Rate-of-change monitoring
The changing of an analog input signal is recorded over an adjustable pe-
riod. If the parameterized rate of change is exceeded the concerning limit
value outputs are switched.Selectable during programming are positive
(ascending), negative (descending) and absolute (ascending or descen-
ding) gradients.
Value change
0...20 mA / 0...5 V 0.5...110.0 % * 0.5 %
4...20 mA / 1...5 V 0.5...112.5 % * 0.5 %
Time range 0.3; 0.5; 0.8; 1.0; ca. 0.25 s

(Display rounded off) 1.3; 1.5; ... 10 s
*at max. 22 mA / 5.5 V
The entire time range of all parameterized gradients must not exceed 20 s.
If the rate-of change is not recordable (e. g. due to an out-of-range signal),

the output z16 (Alarm) is set on 1-signal.
Not used functions

• Not used channels can be inactivated during parameterization.
• Not used limit value outputs with programmed line diagnosis must
be loaded with the minimum load of 12 kΩ.
Displays during operation
Operating mode 7 Segment LED LED Icon 1, 2 Frame round Display Display
Relay
0...109.9 % RDY ERR Icon 1, 2 LB LS
L-Signal at 1, 2 Value ON OFF ON OFF OFF OFF ON

H-Signal at 1, 2 Value ON OFF ON ON OFF OFF ON
IE < 3.6 mA (0.9 V) * Value ON OFF ON OFF ON OFF ON x
ON x OFF
IE > 21 mA (5.25 V) * Value ON OFF ON OFF OFF ON ON x
ON x OFF
LB Value ON ON flashing OFF ON OFF OFF
LS Value ON ON flashing OFF OFF ON OFF
Fault internally ERR OFF ON OFF OFF OFF OFF OFF
Fault analogue ERR OFF ON OFF OFF OFF OFF OFF
Fault digitally Value OFF ON flashing OFF OFF OFF OFF
Programming Value ON flashing ON/OFF ON/OFF OFF OFF OFF
* according to NAMUR NE 43, operation 4...20 mA

x depending on programming
Display of „Value“:
Range 0...22 mA / 0...5.5 V: 0...110 %
Range 4...22 mA / 1...5.5 V: 0...112.5 %
In the operating mode „Rate-of-change“ the value display shows the pre-
sent input value only but not the gradient.
5/20
62 100 (9908)
Display of the parameters during operation

Selection of the parameters like in parameterization mode via left or right
pushbutton MENUE. The display is left when
• all values have been displayed and after actuating the right push-
button MENUE,
• in the first step of the display the left pushbutton MENUE is actua-
ted,
• for 10 seconds no pushbutton is actuated
Displays Statement
Channel not in use
Analogue input value < 3.6 mA / 0.9 V (at 4...20 mA / 1...5 V)
Error code 100: both channels have line break or short-circuit
Error code 101: both channels have line break or short-circuit
Error code 110: difference too large in 1oo2 application
Error code 131: parameterized data are not correct
Other error codes are of no significance to the user
Technical data of the fault indication relay

Contact material Ag alloy, gold-plated
Switching voltage ≤ 30 V = / AC
≥ 10 mV
Switching current ≤ 1 A, ≥ 10 µA
Switching capacity DC ≤ 30 W, non-inductive
Switching capacity AC ≤ 60 VA, cos ϕ > 0.7
Bounce time < 2 ms
Life
mechanical > 107 switching cycles
electrical > 105 switching cycles
(with resistive load and
≤ 0.1 switching cycles/s)
6/20
62 100 (9908)
Control of modules of the HIMA Planar4 System

If the limit value outputs are connected to inputs of safety-related modules
of the HIMA Planar System then the NC principle should be applied (swit-
ching to 0-signal when reaching the limit value) and no line monitoring be
defined for the limit value outputs.
Notes to the safety-related operation and use

The outputs z16 (Alarm), d28 (ERR) and the contact of the fault indication
relay may not be used for safety-related functions.
In operation the analog inputs of the limit monitor 62100 shall be connec-
ted only at
• two electrically isolated signal sources or
• signals sources with a common negative reference potential.A
safety-related operation with electrically connected signal sources
with different reference potential per channel is not permitted.
Screened cables have to be used for the field input circuits, twisted leads
are recommended.
If it is sure that the environment of the transmitter up to the limit monitor is

free from interference and the distance is relatively short (e. g. inside a
metal cabinet) then the cabling can be performed without screened cables
or twisted leads.
The immunity of the analog inputs, however, can only be achieved by
using screened cables.
Recommendations for the use of the limit monitor

according to IEC 61508, SIL 3
• Lines for power supply shall be separated from the input and output
circuits
• The output circuits must be connected with two poles
• Application of a suitable earthing must be regarded
• Measures against power loss, alteration of power supply voltage
and low voltage have to be taken in the power supply 24 V DC of
the system
• The actuating direction in the dangerous situation has to be defined
before commissioning in correspondance with the alteration of the
physical unit
• Measures against rising of the temperature are to be taken outside
of the limit monitor module, e. g. fans in the cabinet
• Recording events in a logbook for operation
A maintenance of the limit monitor is not required. In case of an error the

limit value outputs and the fault indication relay is switched off, the LED
ERR on the front plate of the module is switched on, and the output d28 is
on 1-signal. For safety reasons a failed limit monitor must be removed or
replaced immediately.
7/20
62 100 (9908)
Notes
The display is readable only at ambient temperatures higher than -10°C.
After switching on the power in operating mode RUN (operation) all dis-
play segments are illuminated for approx. 40 seconds during the self tests
of the module. In the operating mode PROG (parameterization) the modu-
le is ready for operation at once.
Entry of the parameters

The parameters of the two channels can be adjusted after having set at
first the mode switch at the upper rim of the PCB into one of the end posi-
tions PROG. For this setting the module must be pulled out of the subrack,
the mode switch has to be set to PROG (parameterize) and then the mo-
dule must be plugged in again. Then it is at once in the first parameteriza-
tion step (cf. table on the following pages).
During mode PROG mode all the outputs are deenergized and the red
LED ERR is flashing.
• The selection of the parameters and the entry of the values is made
by striking the MENUE and VALUE pushbuttons on the front plate
of the module. The stored or entered parameters can be seen on of
the two displays.When striking the right pushbutton MENUE the
entered parameters are shown in the sequence according to the
following table; with the left pushbutton MENUE they are shown in
reverse sequence.With both the pushbuttons VALUE the desired
parameters and values are set or changed into both directions.
• Important: For confirmation of the correct entry the same parame-
ters must be entered in each step at once again: after the first entry
the module switches with the pushbutton MENUE the second entry.
The values of the first entry are shown on the upper display, the
values of the second entry are shown on the lower display.The next
or previous range of parameters can be selected by the pushbut-
tons MENUE only if the entered value is in the permissible range,
and if the first and second entry are identical.
After the last entry and having pressed the pushbutton ACK then for ap-
prox. 1 second the display "Oc" is shown and the new parameters are ac-
cepted. If the values do not correspond, the display shows E01 or E02,
and the values are not accepted. After striking the pushbutton ACK the sy-
stem returns to the first step of the parameter input.
After parameterization pull out the module again, set the mode switch on
the PCB back to the center position RUN and plug in the module into the
subrack again.
8/20
62 100 (9908)
Table: Sequence of parameterization
MENUE VALUE Statement Remarks, explanations
1 Channel selection Cannel 1 selected Selection for parameterization
Channel 2 selected
1oo2 application after step 4 continued with 6
2 Switching off of Selected channel ON Additional displays:

channels not in use
Selected channel OFF Operating mode
Channel number 1 or 2
3 Input signal 4...20 mA / 1...5 V ERR: Switch-off of the outputs

with ERR with input signals out of
4...20 mA / 1...5 V standard range (NE 43)
without ERR
0...20 mA / 0...5 V
4 Line diagnosis Line diagnosis OFF Line diagnosis for

for outputs the limit value outputs
Line diagnosis ON
5 Signal evaluation Limit value (continued with 5.1) Display: for output 1 (2)
Gradient (continued with 5.2)
5.1 Limit value selected: limit value Display: for output 1 (2)
5.1.1 Actuating direction Actuating direction Low Limit value underflow
Actuating direction High Limit value overflow
5.1.2 Setting the flashing digit display Additional display:

limit value for value entry
Selection of the digit with "Menue",
setting of the value with "Value"

hysteresis for value entry
5.1.4 Steps since 5 repeated for the second output, then continued with 7
9/20
62 100 (9908)
MENUE VALUE Statement Remarks, explanations
5.2 Gradient selected: gradient Display: for output 1 (2)
5.2.1 Type positive gradient ascending values
negative gradient descending values
absolute gradient ascending or descending values

value for value entry

time range for value entry
5.2.4 Steps since 5 repeated for the second output, then continued with 7
6 Additional parameterization for 1oo2 application of the sensors
6.1 Steps 5 to 5.1.3 or 5 to 5.2.3 repeated for each of the four outputs, then:
6.2 Evaluation of the Average value

sensors
maximum values
minimum values
6.3 Setting the flashing digit display Additional display:

value discrepancy for value entry
6.4 Selection of Deci-seconds (0.1 s) Additional display:

time basis
Seconds
6.5 Setting the flashing digit display Additional display:

time discrepancy for value entry, as above
Entry like other values
10/20
62 100 (9908)
Entry Display Statement Remarks, explanations
7 Strike pushbutton ACK Additional display:
or or
7.1 Pushbutton ACK Entries stored, display: (for approx. 1 s)
7.2 Pushbutton ACK Entries not stored, display: or
E01: Limit value + hysteresis > permissible range
E02: Limit value - hysteresis < permissible range
Correction of the entries after striking ACK
11/20
62 100 (9908)
1 Operation with a safe transmitter

In this application the first channel is operated with a current input 4...20
mA, the second channel with voltage input 0...5 V.
Transmitter Transmitter
4...20 mA 0...5 V
- + - +
MUX
A A
D D
- + - + - + - +
L-
1 2 1 2
2 1oo2 Operation of sensors with monitoring of the discrepancy

As practically very often only non-safety-related transmitters are available,
two transmitters have to be assembled at the same measuring point to get
the required safety. In this case both of the transmitters are related to the
same two outputs. The permissible discrepancies of values and time peri-
ods are adjusted. If the minimum, average or maximum value of the two
transmitters is lower or higher than the adjusted limit then the related out-
put will be deenergized. Four limit values can be adjusted.
This application can also be used to compare two analog values for a per-
missible difference.
12/20
62 100 (9908)
3 Redundant operation, input voltage 0...5 V

The output voltage of one transmitter is connected in parallel on two inde-
pendent limit monitors 62100. Both of the limit monitors are set to the
same limit value, and their outputs are connected in parallel. The failure of
one limit monitor does not influence the signal of the logic circuit after-
wards. This operating mode does not permit a line monitoring of the output
circuits.
Transmitter
0...5 V
- + - + - + - +
MUX MUX
A A A A
D D D D
Processor Unit 1 1oo2 System Processor Unit 2 Processor Unit 1 1oo2 System Processor Unit 2
Module 1 Module 2
- + - + - + - + - + - + - + - +
L- L-
1 2 1 2
4 Redundant operation, current input 4...20 mA

The current of one transmitter is lead to two independent limit monitors
62100. This application requests an additional resistor outside of the limit
monitor. Both of the limit monitors are set to the same limit values, and the
outputs are connected in parallel. The failure of one limit monitor does not
influence the signal of the logic circuit afterwards. This operating mode
does not permit a line monitoring of the output circuits.
Transmitter
Resistor 250 Ω / 0.05 %
4...20 mA
HIMA Part no. 000710251
- + - + - + - +
MUX MUX
A A A A
D D D D
Module 1 Module 2
- + - + - + - + - + - + - + - +
L- L-
1 2 1 2
13/20
62 100 (9908)
5 Redundant operation, open-circuit principle

with current input 4..20 mA
The output current of one transmitter is connected in series on two inde-
pendent limit monitors 62100. This application requires an additional resi-
stor outside of one limit monitor. Both of the limit monitors are set to the
same limit values and their outputs are connected in parallel and decou-
pled by diodes. The line diagnostic of the output circuit is active. The failu-
re of one limit monitor does not influence the signal of the logic circuit
afterwards.
Transmitter
Resistor 250 Ω / 0.05 %
4...20 mA
HIMA Part no. 000710251
- + - + - + - +
MUX MUX
A A A A
D D D D
Module 1 Module 2
- + - + - + - + - + - + - + - +
L- L-
1 2 1 2
12 kΩ 12 kΩ
6 Operation mode for more than two limits per transmitter

The current (voltage of channel 1) of one transmitter is connected also on
the second channel of the limit monitor.
Transmitter
0/4...20 mA
- + - +
MUX
A A
D D
- + - + - + - +
L-
1 2 1 2
14/20
62 100 (9908)
Kommunikation via MODBUS


0 WORD F1 H Module type 62 100
1 BOOL 0 none
7...24 BOOL 0 none
25 WORD * Actual value channel 1
26 WORD * Actual value channel 2
27 BOOL 1 1-signal at output d18, channel 1/1 24
31 BOOL 1 1-signal at output z16, Alarm 28
32...34 BOOL 0 none
35 WORD * Channel 1, limit value 1

* Range 0...1125 in steps of 0.1 % (0...112.5 %)

since address 2000 H
Rel. address 0 8......1 25 26 34 . . . . . . 27
Data Mod. type Mod. state Actual value channel 1 Actual value channel 2 none outputs

Rel. address 0 8......1 35 36 34 . . . . . . 27
Data Mod. type Mod. state Additional information Additional information none outputs
Channel 1, limit value 1 Channel 1, limit value 2
15/20
62 100 (9908)

Rel. address 0 8......1 37 38 34 . . . . . . 27
Data Mod. type Mod. state Additional information Additional information none outputs
Channel 2, limit value 1 Channel 2, limit value 2
Additional information
Bit no. Channel parameterization

0 1 2 3
0 Channel not in use
1 Channel in use
0 0 0 Actuating direction of the limit value: L (Low)
0 0 1 Actuating direction of the limit value: H (High)
1 0 0 Rate-of-change monitoring: positive gradient
1 0 1 Rate-of-change monitoring: negative gradient
1 1 0 Rate-of-change monitoring: absolute gradient
For a faultless data transfer always all 84 words must be read. With that
all the variables of the modules of one subrack are transferred. For module
locations not in use the values 0 are transferred.
16/20
62 100 (9908)

State of the module, signals at the outputs

0...7 0 0...7 F1 H Module type 62 100
8 0 0 none
14 6 0 none
15 7 0 none
1...2 2...5 0 none
0 0 1 1-signal at output d18, channel 1/1
2 6 2 1 1-signal at output d22, channel 2/1
4 4 1 1-signal at output z16, Alarm
5...7 5...7 0 none
8...15 7 0...7 0 none

17/20
62 100 (9908)

State of the module, actual values, signals at the outputs
WORD Bit BYTE Bit Wert Bedeutung

0...7 0 0...7 F1 H Module type 62 100
8 0 0 none
14 6 0 none
15 7 0 none
1 8...15 2 0...7 0...127 Actual value channel 1 (high byte) in 0.1 %
0...7 3 0...7 0...127 Actual value channel 1 (low byte) in 0.1 %
2 8...15 4 0...7 0...127 Actual value channel 2 (high byte) in 0.1 %
0...7 5 0...7 0...127 Actual value channel 2 (low byte) in 0.1 %
4 4 1 1-signal at output z16, Alarm
5...7 5...7 0 none
8...15 7 0...7 0 none

18/20
62 100 (9908)

Limit values, actuating direction, gradient
WORD Bit BYTE Bit Wert Bedeutung

15 7 1 Channel in operation
000 Actuating direction of the limit value: L (Low)
14...12 6...4 001 Actuating direction of the limit value: H (High)
101 Rate-of-change monitoring: negative gradient
110 Rate-of-change monitoring: absolute gradient
0...11 0...3 0...15 Limit value channel 1, output 1 (high byte) in 0.1 %
1 0...7 0...127 Limit value channel 1, output 1 (low byte) in 0.1 %

19/20
Analogue Limit Monitor 62 100
Plant ______________________________________ Building _____________ Switchroom___________
Parameterization of the module: Cabinet / Rack _________ Subrack ________ Module location _______
Channel 1 _________________________________ Channel 2 _________________________________
q 1oo2 operation of the sensors
q 4...20 mA / 1...5 V (with switch-off*) q 4...20 mA / 1...5 V (with switch-off*)

Channel 1 Channel 1
q 4...20 mA / 1...5 V (alarm only*) q 4...20 mA / 1...5 V (alarm only*)

Input Input
q 0...20 mA / 0...5 V q 0...20 mA / 0...5 V

* when leaving the admissible input range * when leaving the admissible input range
q ON q ON
q OFF q OFF
Line diagnosis of the outputs Line diagnosis of the outputs
Signal evaluation of output d18 ______________ Signal evaluation of output d22 ______________
q Limit value __________ % q Limit value __________ %
Hysteresis __________ % Hysteresis __________ %
q Rate of Change ______ % per __________ s q Rate of Change ______ % per __________ s
q positive q negative q absolut q positive q negative q absolut
Switching direction q Low q High Switching direction q Low q High
Signal evaluation of output d20 ______________ Signal evaluation of output d24 ______________
q Limit value __________ % q Limit value __________ %
Hysteresis __________ % Hysteresis __________ %
q Rate of Change ______ % per __________ s q Rate of Change ______ % per __________ s
q positive q negative q absolut q positive q negative q absolut
Switching direction q Low q High Switching direction q Low q High
1oo2 operation of the sensors
q Average value
q Maximum value
Evaluation of the sensors
q Minimum value
Admissible value discrepancy___________ %
Admissible time discrepancy ___________ s
Remarks
__________________________________________ __________________________________________
__________________________________________ __________________________________________
__________________________________________ __________________________________________
__________________________________________ __________________________________________
Made ______________ Approved ________________ Date ____________ Signature _________________

80 100 (9908)
80 100
Communication Module 80 100
for data transfer from the Planar4 System
via MODBUS
80 100
RUN ERR
Tx Col RS
RS 485
10BaseT
The communication module is used to transfer data from the modules of

the Planar4 System to other systems.
Up to 21 modules of the Planar4 System can be connected to the input

channels (z2-z4, z6-z8, ... d26-d28) for internal communication. For this
application the Planar4 subracks with bus PCB should be used which al-
ready contain the necessary connections. The module locations 1...20 of
these subracks are provided for Planar4 modules, the 21st location is re-
served for the communication module.
The data transfer to other systems with this module is made via MODBUS,
connector RS 485.
The data transfer via MODBUS is described in the chapter “Communica-

tion” in the Planar4 system manual.
Processor 32 bit
Main memory 4...16 MB
Connections RS 485 (semi-duplex)
RJ-45 (not used)
80 100 (9908)
After switching on the power supply a memory test is proceeded; during

this time the displays RUN and ERR are flashing synchronously. If RUN is
on and ERR is flashing, there is a communication error between the
Planar4 modules and the communication module.
LED displays
RUN Module is ready for operation or
in operation without error
ERR Module is in an error state
Tx not used
Col not used
RS Interface RS 485 in operation
Switches for settings

The communication modules are connected to a bus system via an inter-
face RS 485. Each module is a MODBUS slave with an own slave number;
the setting of the number is made with switches on the module.
Setting of the MODBUS slave no.
2/4
80 100 (9908)

the entire quantity of slaves is limited to 124.
For MODBUS data transfer the module has a standard setting to: 1 stop
bit, parity bit even. This setting cannot be changed.
Pin occupation of the interface RS 485
Pin RS 485 Signal Function
1 - Screen Screening, protective earth

2 - RP 5 V, decoupled by diodes
3 A/A’ RxD / TxD-A Receive/Transmit data A
4 - CNTR-A Control signal A
5 C/C’ DGND Data ground
6 - VP 5 V, positive pole of supply voltage
7 not used
8 B/B’ RxD / TxD-B Receive/Transmit data B
9 - CNTR-B Control signal B
Note
For using the communication module outside a Planar4 subrack with bus
PCB it is important for the wiring that the communication lines between the
Planar4 modules and the communication module are twisted in pairs and
additionally screened if possible. The line must be connected with correct
polarity and may not exceed the length of one meter. The screens must
have a single-end connection to earth.
3/4
80 100 (9908)
For your notes
4/4
80 101 (9908)
80 101
via Profibus-DP
80 101
RUN ERR
Tx Col RS
RS 485
10BaseT


The data transfer to other systems is made via Profibus-DP, connector RS

485.
The data transfer via Profibus-DP is described in the chapter “Communi-

cation” in the Planar4 system manual.
Processor 32 bit
Connections RS 485 (semi-duplex)
RJ-45 (not used)
80 101 (9908)

LED displays
Tx not used
Col not used
RS Interface RS 485 in operation

The communication modules are connected to a bus system via an inter-
face RS 485. Each module is a Profibus slave with an own slave number;
the setting of the number is made with switches on the module.
Setting of the Profibus slave no.
2/4
80 101 (9908)

the entire quantity of slaves is limited to 124.
For Profibus data transfer the module has a standard setting to: 1 stop bit,
parity bit even. This setting cannot be changed.
Pin occupation of the interface RS 485
Pin RS 485 Signal Function
1 - Screen Screening, protective earth

2 - RP 5 V, decoupled by diodes
3 A/A’ RxD / TxD-A Receive/Transmit data A
4 - CNTR-A Control signal A
5 C/C’ DGND Data ground
6 - VP 5 V, positive pole of supply voltage
7 not used
8 B/B’ RxD / TxD-B Receive/Transmit data B
9 - CNTR-B Control signal B
Note
3/4
80 101 (9908)
For your notes
4/4
80 102 (9908)
80 102
via Ethernet (with OPC-Server)
80 102
RUN ERR
Tx Col RS
RS 485
10BaseT


The data transfer to other systems is made via Ethernet (with OPC ser-
ver), connector RJ-45.
The data transfer via Ethernet is described in the chapter “Communicati-

on” in the Planar4 system manual and in the manual “HIMA OPC Server”.
Processor 32 bit
Connections RS 485 (not used)
RJ-45 (10BaseT)
for Ethernet OPCserver
80 102 (9908)

LED displays
Tx Ethernet interface transmitting
Col Collision display for EN network
RS (no function)
Communication via Ethernet

The communication modules are connected with a twisted-pair cable via
the RJ-45 connector to an Ethernet hub which is linked to the Ethernet
card of the OPC server. Each communication module module has an own
ID number; the setting (0...127) is made with switches on the module.
Setting of the ID number
2/4
80 102 (9908)
Pin occupation of the connector RJ-45

RJ-45 is an 8-pole connector, internationally standardized for the linkage
of STP/UTP lines according to IEEE 8023 (10BaseT).
Pin Nr. Signal Funktion
1 TD+ Transmit data +

2 TD - Transmit data -
3 RD + Receive data +
4 not used
5 not used
6 RD - Receive data -
7 not used
8 not used
Note
3/4
80 102 (9908)
For your notes
4/4
90 100 (9906)
90 100
4-fold Fuse Module 90 100
d30 with fuse monitoring and LED display
b10
d10
b14
d14
z30
z10
z14
b2
d2
b6
d6
z2
z6
90 100
RDY
ERR
FF
F1
EL+
F2
F3
DCM RDY F4
F1 F2 F3 F4
FF ERR F1
COM ERR
F2
+ -
F3
L-
F4
F1 F2 F3 F4 5F
d12
d16
b28
d28
b26
d26
b32
d32
z32
z28
z26
d4
d8
F1... F4 Delivery state 4 A time-lag
The module has six fused current paths. Only the fuses of the current
paths connected to the supply voltage are monitored.
The voltage supply is connected to the pins z2, b2, d2 (z6, b6, d6; z10,
b10, d10; z14, b14, d14). Normal operation is indicated for each current
path by steady light of the appertaining LED (F1, F2, F3, F4) on the front
plate. With a current path not connected the appertaining LED is off and
the fuse is not monitored.
When a fuse blows the appertaining LED indicates flashing light, and FF
is in steady light.
The displays and the signals are described on the reverse of this data
sheet.
Fuses ≤ 4 A time-lag
Delivery state: 4 A time-lag
90 100 (9906)
Function table
Input Fuse LEDs LED LED Input Signal

F1...F4 FF ERR d28
⊗ ⊗
L+ o.k. 0
⊗
L+ blown 1
⊗⇔
0
⊗ ⊗ ⊗ 0
internal fault 1
⊗ LED off LED on

An internal malfunction (not a blown fuse) is indicated by ERR, the output
d28 is on 1-signal and the relay contact z26-d26 opens.
2/4
90 100 (9906)


1 BOOL 0 none
7 BOOL 1 Fuse fault, FF
8 BOOL 0 none
9 BOOL 1 Voltage at z2-b2-d2 0
13...40 BOOL 0 none
41 BOOL 1 Voltage at d4 24
45...48 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
3/4
90 100 (9906)


0...7 0 0...7 91 H Module type 90 100
8 0 0 none
14 6 0 none
15 7 0 none
0 0 1 Voltage at z2-b2-d2
1 2 2 2 1 Voltage at z10-b10-d10
4...7 4...7 0 none
8...15 3 0...7 0 none
2 4...5 0 none
0 0 1 Voltage at d4
1 1 1 Voltage at d8
3 2 6 2 1 Voltage at d12
3 3 1 Voltage at d16
4...7 4...7 0 none
8...15 7 0...7 0 none

4/4
90 300 (9906)
90 300
2-fold Bypass Module 90 300
with non-interacting LED display
90 300
RDY
ERR
I1
B1
I2
B2
S1
S2
The bypass module indicates a present 1-signal on the signal path of the
module by means of the LED I1 (I2). This signal can be bypassed by a lin-
kage of the connector pins d2-z8 (d4-d8) and by operation of the switch
S1 (S2) on the front plate of the module. The bypassed state is indicated
by the red LED B1 (B2). A common display of all operated override swit-
ches is possible by connections of all pins z10 and d10 to a busbar.
Each override switch is provided with a floating changeover contact con-

nected to the pins.

Fuse 0.375 A
Switching contact ≤ 30 V, ≤ 2 A
90 300 (9906)


1 BOOL 0 none
7...8 BOOL 0 none
9 BOOL 1 1-signal at input z2, I1 0
10 BOOL 1 1-signal at input z4, I2 1
11...16 BOOL 0 none
17 BOOL 1 Bypass switch S1 ON 8
17 BOOL 1 Bypass switch S2 ON 9
19...40 BOOL 0 none


Rel. address 0 8 . . . . . . 1 24 . . . . . . 17 16 . . . . . . 9 40 . . . . . . 33 32 . . . . . . 25 48 . . . . . . 41
Data Mod. type Mod. state Schalter Inputs none none none Outputs
2/4
90 300 (9906)


0...7 0 0...7 92 H Module type 90 300
8 0 0 none
14 6 0 none
15 7 0 none
0 0 1 1-signal at input z2 I1
1 2 1 1 1-signal at input z4 I2
1 2...7 2...7 0 none
8 0 1 Bypass switch S1 ON
9 3 1 1 Bypass switch S2 ON
10...15 2...7 0 none
2 4...5 0 none
3 4 4 1 1-signal at output d4
8...15 7 0...7 0 none

3/4
90 300 (9906)
For your notes
4/4
90 900 (9850)
90 900
Subrack with bus PCB 90 900
for modules of the HIMA Planar4 System
Connection: pins for soldering
Delivery without modules
The subrack is used only for the HIMA Planar4 System. The module loca-
tions 1...20 are provided for any modules of the Planar4 System, location
21 is reserved for the communication module.
The bus PCB at the rear side contains socket connectors, connection
strips (soldering type) as well as the bus structure necessary for function:
connections for the internal communication, operating voltage supply
24 VD C, common busbar and contact loop for the fault signals. For the
data connecting cable of the communication module a penetration is pro-
vided to the wiring area at the rear.
The subrack is completely mounted including a labelling field at the front

and a cable duct at the rear side.
Material Aluminium, chromated

Width 482.6 mm (19 inches)
Height 177 mm (4 Units)
Depth 270 mm
Spacing units 84 SU (1 SU = 5.08 mm)
Modules according to DIN 41494,
4 SU each
Connectors DIN 41612, design F,
with rows z and d
Connection type soldering
90 900 (9850)
Principle of the bus PCB

Rear view
The connection of the supply voltage EL+ is made without use of a fuse
module directly via a fuse or circuit breaker of max. 16 A (wire cross-sec-
tion 2.5 mm2).
For safety reasons the reference pole L- must be connected from two se-
parated terminals on the L- distribution bar to both plug terminal blocks
XG.1 and XG.6 (ring feeder).
In order to avoid high total currents the second supply terminals for EL+
and L- on XG.1 and XG.6 should not be used for feeding more subracks.
The plug terminal blocks XG.2, XG.3, XG.4 and XG.5 are floating; the con-
nection pins of one block are linked on the PCB. The blocks may be used
depending on requirements.
For the feeding of power outputs via the plug terminal blocks XG.2 up to
XG.5 separate supply lines with suitable wire cross-sections should be
used for L+ and L- (cf. also chapter “Wiring of the Subracks” in the system
manual). The current loading is limited to max. 16A.
In order to keep mechanical stress low to the soldering points at the con-
nection pins, the plug terminal blocks should be pulled out from their sok-
The earth connections b30 have electrically conductive bonding with the
metal parts of the subrack. The pins z28, b28, d28, z30 ... d32 at the rear
connection strips have no connection to the bus PCB.
2/4
90 900 (9850)
When using the contact loop for the fault signal, on all not used module
locations the pins z26-d26 must be linked or connected to one of the ter-
minals EC.
The use of (Ex)i modules of the Planar4 System is possible when the con-
nection strips at the rear of the bus PCB are replaced by (Ex) types.
When the feature of the data communication to other systems is re-

nounced, for the Planar4 System also standard subracks with 32-pole
socket connectors may be used.
3/4
90 900 (9850)
For your notes
4/4
90 901 (9850)
90 901
for (Ex)i modules of the HIMA Planar4 System
Connection: pins for soldering
tions 1...20 are provided for (Ex)i modules of the Planar4 System, location
strips (soldering type) as well as the bus structure necessary for function:
connections for the internal communication, operating voltage supply
24 VD C, common busbar and contact loop for the fault signals. For the
data connecting cable of the communication module a penetration is pro-
vided to the wiring area at the rear.


Depth 270 mm
4 SU each
with rows z and d
Connection type soldering
90 901 (9850)

Rear view
tion 2.5 mm2).
2/4
90 901 (9850)
minals EC.
The use of other modules of the Planar4 System is possible when the (Ex)i
connection strips at the rear of the bus PCB are replaced by normal types.

3/4
90 901 (9850)
For your notes
4/4
90 902 (9850)
90 902
for modules of the HIMA Planar4 System
Connection: pins for termi-point / wire-wrap
tions 1...20 are provided for any modules of the Planar4 System, location
strips (termi-point/wire-wrap type) as well as the bus structure necessary
for function: connections for the internal communication, operating voltage
supply 24 V DC, common busbar and contact loop for the fault signals. For
the data connecting cable of the communication module a penetration is
provided to the wiring area at the rear.


Depth 270 mm
4 SU each
with rows z and d
Connection type termi-point / wire-wrap,
posts 0.8 x 1.6 mm
90 902 (9850)

Rear view
tion 2.5 mm2).
2/4
90 902 (9850)
minals EC.
The use of (Ex)i modules of the Planar4 System is possible when the con-
nection strips at the rear of the bus PCB are replaced by (Ex) types.

3/4
90 902 (9850)
For your notes
4/4
90 903 (9850)
90 903
for (Ex)i modules of the HIMA Planar4 System
Connection: pins for termi-point / wire-wrap
tions 1...20 are provided for (Ex)i modules of the Planar4 System, location
strips (termi-point/wire-wrap type) as well as the bus structure necessary
for function: connections for the internal communication, operating voltage
supply 24 VD C, common busbar and contact loop for the fault signals. For
the data connecting cable of the communication module a penetration is
provided to the wiring area at the rear.
The subrack is completely mounted including a labelling field at the front,

wiring protective covers and two cable ducts at the rear side.

Depth 270 mm
4 SU each
with rows z and d
Connection type termi-point / wire-wrap,
posts 0.8 x 1.6 mm
90 903 (9850)

Rear view
tion 2.5 mm2).
2/4
90 903 (9850)
minals EC.
The use of other modules of the Planar4 System is possible when the (Ex)i
connection strips at the rear of the bus PCB are replaced by normal types.

3/4
90 903 (9850)
For your notes
4/4
From:
Company:
Name:
Dept.:
HIMA Paul Hildebrandt GmbH + Co KG Address:
Documentation
P.O. Box 1261
68777 Brühl Phone:
Germany Fax:
Date
Dear reader,
we are always eager to keep our manuals up to date and to avoid errors. But if you have found an
error in this manual, or if you want to make suggestions for improvements, also for the HIMA pro-
ducts, we would be very grateful to you.
Please use therefore just this page or a photocopy of it and send it to us by post or by fax.
(Fax No. (+49) 6202 709-123)
Sub.: System Manual Planar4

HK 99.10 E
HIMA
... the safe decision.
HIMA Paul Hildebrandt GmbH + Co KG

P.O. Box 1261 • 68777 Brühl • Germany
HK 99.10 E Telephone: (+49 6202) 7 09-0 • Telefax: (+40 6202) 7 09-1 07
(9917) E-mail: info@hima.com • Internet: www.hima.com 0499.10

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Electronic Systems

HIMA Paul Hildebrandt GmbH + Co KG

The technology is subject to changes without notice.

Conditions of Supply and Delivery

1 The HIMA Planar4 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

and Earth Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1 The HIMA Planar4 System

The awareness of environmental issues of today, the safety orientation as

The possible hazard of big industrial plants or in traffic technology lies in

The HIMA Planar4 System represents a modular electronic circuit system

1.1 Safety-Related Modules

In the common electronic control modules DC voltage signals are proces-

Fig. 1 shows the principle structure of a safety-related AND element as an

Fig. 1: AND function in safety-related design

1.2 Diagnosis and Error Indication

A diagnosis and communication subassembly (DCM) integrated on each

Fig. 2: Diagnosis and communication subassembly

1.3 Communication with other Sytems

The following information can be read out from the modules:

– signal states of all inputs and outputs,

– residual delay of time delay elements,actual values and limit values of

The communication with other systems has a three-level structure:

– communication internally on each module with the diagnosis and com-

– communication externally between the communication module and

A detailed description of the communication to other systems can be found

2 Functions of the Modules in the

2.1 Input Modules

If mechanical contacts are used for input modules instead of proximity

2.2 Output Modules

2.3 Relay Modules

2.4 Logic Function Modules

2.5 Time Delay Modules

2.6 Analogue Limit Monitor

2.7 Communication Modules

2.8 Modules for Power Supply,

2.9 Intrinsically Safe Circuits and Modules

In the Planar4 System two variants are applicated:

These installations are called “corresponding electric installations”.

Intrinsically safe amplifiers are used for transmitting control commands

The intrinsically safe parts of corresponding electric installations are divi-

Example of a designation for the control circuit of a corresponding electri-

II(1)G [EEx ia] IIC (according to european guidelines)

II Operation range: device group

Modules with intrinsically safe circuits have an EC Prototype Test Certifi-

The number of the certificate contains statements as shown in the follo-

PTB 97 ATEX 2164 X (according to european guidelines)

PTB Testing authority

The indication of specific conditions (X) are e. g. notes on:

• Use of power supplies with safe isolation

2.10 Current Circuits with Safe Isolation

– Overvoltage class III

For your notes

3.1 Operating Voltage

Nominal voltage 24 V DC, -15...+20 %,

3.2 Voltage Supply

L+ positive pole (power voltage)

The EL+ is defined to be a voltage which is able to compensate voltage

High current peaks (e. g. caused by lamps, 7...10-fold nominal current)

Fig. 3: Principle of supply with decoupling