d HIMax Maintenance Manual MAINTENANCE
All HIMA products mentioned in this manual are protected by the HIMA trade-mark. Unless noted otherwise, this also applies to other manufacturers and their respective products referred to herein. All of the instructions and technical specifications in this manual have been written with great care and effective quality assurance measures have been implemented to ensure their validity. For questions, please contact HIMA directly. HIMA appreciates any suggestion on which information should be included in the manual. Equipment subject to change without notice. HIMA also reserves the right to modify the written material without prior notice. For further information, refer to the HIMA DVD and our website http://www.hima.de and http://www.hima.com. Copyright 2010, HIMA Paul Hildebrandt GmbH + Co KG All rights reserved Contact HIMA Address HIMA Paul Hildebrandt GmbH + Co KG P.O. Box 1261 68777 Brühl, Germany Tel: +49 6202 709-0 Fax: +49 6202 709-107 E-mail: info@hima.com Revision index Revisions 1.00 First issue Type of Change technical editorial HI 801 171 E Rev. 1.00 (1033)
Maintenance Table of Contents Table of Contents 1 Introduction... 5 2 Operating and Servicing Activities... 6 3 Other Applicable Documents... 7 4 Proof Test... 8 4.1 Proof Test Execution... 8 4.2 Frequency of Proof Tests... 8 5 Maintenance Actions, in Details... 9 5.1 Replacing System Fans... 9 5.2 Maintenance Actions for Modules... 9 5.2.1 Replacing the Module... 9 5.2.1.1 Prior to Replacing Redundant Modules... 9 5.2.1.2 Prior to Replacing Non-Redundant Modules... 9 5.2.2 Mounting and Removing the Module... 10 5.2.3 Loading the Operating System... 11 5.2.4 Maintenance Indicators... 12 5.3 Field Termination Assemblies... 12 5.4 Base Plate... 13 Appendix... 15 Index of Figures... 15 Index of Tables... 15 HI 801 171 E Rev. 1.00 Page 3 of 16
Table of Contents Maintenance Page 4 of 16 HI 801 171 E Rev. 1.00
Maintenance 1 Introduction 1 Introduction This document describes the most important activities for servicing or operating a safetyrelated HIMax controller. Chapter 2 provides a table with the overview of the activities. Chapter 3 specifies the relevant manuals and other documents. Chapter 4 describes the proof test. Chapter 5 describes in detail the required maintenance actions and provides references to further documents. HI 801 171 E Rev. 1.00 Page 5 of 16
2 Operating and Servicing Activities Maintenance 2 Operating and Servicing Activities No. Activity Period Reference (Table 2) Performed 1 Access protection (security) Always - A Mechanical test (visual inspection) 2 Are the modules screwed tightly? Yearly - C, A, O 3 Are the cable plugs screwed tightly? Yearly - C, A, O 4 Are the data connection cables (communication Yearly - C, A, O modules) screwed tightly? Power supply test 5 Check 230 VAC/24 VDC Yearly - C, A, O 6 Check 24 VDC distribution Yearly - C, A, O 7 Functionality with redundant supply Yearly - C, A, O Proof Test 8 Loop test including the I/O modules within the PES 10 years D2 Chapter 4 by 1) C, A, O The modules used for safety-related application must be subjected to a proof test at regular intervals (refer to IEC/EN 61508-4, Section 3.8.5) Hardware change/extension/test 9 Replacement of the modules If required D1, D2, D5 Chapter 5.2.1, 5.2.2 C, A, O 10 Replacement of the system fans D4 C, A, O At an operating temperature of Every 6 years Chapter 5.1 40 C At an operating temperature of > 40 C Every 3 years Software change/extension/test 11 Load and deletion of the user program If required D3 C, A, O 12 Operating system download If required D3, Chapter 5.2.3 C, A, O 13 Change of the system parameter settings 1) C: operating Company, A: Assembler, O: Other Table 1: If required Required Operating and Maintenance Activities D1 D5 C, A, O Notes Only personnel with knowledge of ESD protective measures may modify or extend the system or replace modules. NOTE Device damage due to electrostatic discharge! When performing the work, make sure that the workspace is free of static, and wear an ESD wrist strap. If not used, ensure that the device is protected from electrostatic discharge, e.g., by storing it in its packaging. Page 6 of 16 HI 801 171 E Rev. 1.00
Maintenance 3 Other Applicable Documents 3 Other Applicable Documents Ref. Standard/Document Description N1 IEC 61511-1, Section 12 Functional safety - Safety instrumented systems for the process industry sector Framework, definitions, system, hardware and software requirements D1 HI 801 001 E HIMax System Manual D2 HI 801 003 E HIMax Safety Manual D3 - SILworX Online Help D4 HI 801 033 E X-FAN Manual D5 Module Manuals HI 801 025 E HIMax X-BASE PLATE 01 Manual HI 801 021 E HIMax X-AI 32 01 Module Manual HI 801 055 E HIMax X-AI 32 02 SOE Module Manual HI 801 111 E HIMax X-AO 16 01 Module Manual HI 801 113 E HIMax X-CI 24 01 Module Manual HI 801 011 E HIMax X-COM 01 Module Manual HI 801 009 E HIMax X-CPU 01 Module Manual HI 801 057 E HIMax X-DI 16 01 Module Manual HI 801 015 E HIMax X-DI 32 01 Module Manual HI 801 017 E HIMax X-DI 32 02 Module Manual HI 801 059 E HIMax X-DI 32 03 Module Manual HI 801 057 E HIMax X-DI 32 04 SOE Module Manual HI 801 053 E HIMax X-DI 32 05 SOE Module Manual HI 801 093 E HIMax X-DI 64 01 Module Manual HI 801 023 E HIMax X-DO 12 01 Module Manual HI 801 099 E HIMax X-DO 12 02 Module Manual HI 801 019 E HIMax X-DO 24 01 Module Manual HI 801 095 E HIMax X-DO 24 02 Module Manual HI 801 097 E HIMax X-DO 32 01 Module Manual HI 801 007 E HIMax X-SB 01 Module Manual HI 801 115 E HIMax X-FTA 001 01 Manual HI 801 131 E HIMax X-FTA 001 02 Manual HI 801 117 E HIMax X-FTA 002 01 Manual HI 801 119 E HIMax X-FTA 002 02 Manual HI 801 121 E HIMax X-FTA 003 02 Manual HI 801 125 E HIMax X-FTA 005 02 Manual HI 801 127 E HIMax X-FTA 006 01 Manual HI 801 129 E HIMax X-FTA 006 02 Manual HI 801 133 E HIMax X-FTA 007 02 Manual HI 801 135 E HIMax X-FTA 008 02 Manual HI 801 137 E HIMax X-FTA 009 02 Manual Table 2: Valid Documentation HI 801 171 E Rev. 1.00 Page 7 of 16
4 Proof Test Maintenance 4 Proof Test The proof test reveals dangerous undetected faults that could otherwise affect the safe function of the system. HIMA safety systems must be subjected to a proof test in intervals of 10 years. It is often possible to extend this interval using the a calculation tool to analyze the implemented safety loops. 4.1 Proof Test Execution The proof test execution depends on the following factors: Plant characteristics (EUC = equipment under control) Plant's intrinsic risk potential The standards applicable to the plant operation and required for approval by the responsible test authority. According to IEC 61508 1-7, IEC 61511 1-3, IEC 62061 and VDI/VDE 2180 sheets 1 to 4, the operator of the safety-related systems is responsible for performing the proof tests. 4.2 Frequency of Proof Tests The HIMA PES can be proof tested by executing the full safety loop. In practice, shorter proof test intervals are required for the input and output field devices (e.g., every 6 or 12 months) than for the HIMA controller. Testing the entire safety loop together with a field device automatically includes the test of the HIMA controller. There is therefore no need to perform additional proof tests of the HIMA controller. If the proof test of the field devices does not include the HIMA controller, the HIMA controller must be tested at least once every 10 years. This can be achieved by restarting the HIMA controller. Additional proof test requirements for specific modules are described in the manual of the corresponding module. Page 8 of 16 HI 801 171 E Rev. 1.00
Maintenance 5 Maintenance Actions, in Details 5 Maintenance Actions, in Details This chapter describes the maintenance actions for the components of the HIMax system. i Only qualified personnel may perform maintenance actions to supply, signal and data lines, taking all ESD protection measures into account. Personnel must be electrostatically discharged prior to any direct contact with these supply ore signal lines! 5.1 Replacing System Fans The frequency with which the system fans are replaced depends on the operating temperature. HIMA recommends observing the instructions for replacing the system fans and sending them back to HIMA for overhauling: Refer to the manual of the system fan (HI 801 033 E) for more details. 5.2 Maintenance Actions for Modules Perform the following maintenance actions for modules: If the module fails, observe the instructions specified below to replace it: Operating system download Proof test, see Chapter 4 For further details of maintenance actions, refer to the corresponding module manual. 5.2.1 Replacing the Module If failures occur, the defective module must be replaced with a faultless module of the same type or with an approved replacement model. When replacing modules, observe the instructions specified in the System Manual (HI 801 001 E) and Safety Manual (HI 801 003 E). Chapter 5.2.2 describes the procedure for replacing modules. 5.2.1.1 Prior to Replacing Redundant Modules The HIMax system allows one to operate modules redundantly. If at least one redundant module has been configured for the module to be replaced, the complete system operability can be ensured during the module replacement. Make sure that the redundant module is not disturbed during operation. To this end, observe the LED indicators: The FAULT LED must not be lit. The RUN LED must be lit. If these conditions cannot be ensured, observe the procedure for replacing non-redundant modules. 5.2.1.2 Prior to Replacing Non-Redundant Modules A part of the controller's functions or the entire controller may be put out of operation by removing a non-redundant module. Usually, a part of the functions is no longer available due to the module failure. Prior to replacing the module, take the consequences of the replacement on the entire process into account. If necessary, further technical and organizational measures must be taken to ensure that the process during the module replacement is sufficiently monitored in terms of safety. HI 801 171 E Rev. 1.00 Page 9 of 16
5 Maintenance Actions, in Details Maintenance For more information refer to the TÜV document Maintenance Override. This document is available on the TÜV homepage: http://www.tuv-fs.com or http://www.tuvasi.com. 5.2.2 Mounting and Removing the Module This chapter describes how to mount and remove the HIMax module. A module can be mounted and removed while the HIMax system is operating. NOTE Damage to bus and power sockets due to module jamming! Failure to observe this can damage the controller. Always take care when inserting the module in the base plate. Tools and utilities Screwdriver, slotted 0.8 x 4.0 mm Screwdriver, slotted 1.2 x 8.0 mm Installation 1. Open the cover plate on the fan rack: Move the locks to the open position. Lift the cover plate and insert into the fan rack 2. Insert the top of the module into the hook-in rail, see. 3. Swivel the lower edge of the module towards the base plate and apply light pressure to snap it into place, see. 4. Tighten the screws, see. 5. Pull the cover plate out of the fan rack and close it. 6. Lock the cover plate. Removal 1. Open the cover plate on the fan rack: Move the locks to the open position. Lift the cover plate and insert into the fan rack 2. Release the screw. 3. Swivel the lower edge of the module away from the base plate. Lift and apply light pressure to remove the module from the hook-in rail, see and. 4. Pull the cover plate out of the fan rack and close it. 5. Lock the cover plate. Page 10 of 16 HI 801 171 E Rev. 1.00
Maintenance 5 Maintenance Actions, in Details Inserting and Removing a Module Swiveling a Module in and out Securing and Releasing a Module Figure 1: Mounting and Removing a Module i If the HIMax system is operating, do not open the cover plate of the fan rack for more than a few minutes (< 10 min) since this affects the forced cooling. 5.2.3 Loading the Operating System HIMA is continuously improving the operating system of the module. HIMA recommends to use system downtimes to load the current version of the operating system into the module. For detailed instructions on how to load the operating system, see the System Manual (HI 801 001 E) and SILworX online help. The module must be in STOP to be able to load an operating system. i The current version of the module in use is displayed in the SILworX Control Panel or on the type label! If the module to be loaded is a system module or a processor module the Ess LED must not be lit. HI 801 171 E Rev. 1.00 Page 11 of 16
5 Maintenance Actions, in Details Maintenance The operating system may be loaded during operation if a redundant module has been configured for the module to be replaced. Observe the following instructions: The redundant module must be in the RUN state. - The FAULT LED must not be lit. - The RUN LED must be lit The displayed watchdog buffer time must be sufficiently high to allow the transfer of the operating system. 5.2.4 Maintenance Indicators The maintenance LEDs are labeled Maint. LED Color Status Description Force Yellow On Forcing prepared, processor module in STOP, RUN or OPERATE Blinking1 Forcing active, processor module in RUN or OPER- ATE Off Forcing inactive Test Yellow On Connection to the PADT with write permission Blinking1 One user program is in RUN_FREEZE, (single step operation) Off No connection to the PADT with write permission Prog Yellow On Download (processor module in STOP), the configuration is being loaded Blinking1 Reload procedure active or exchange of configuration data between processor modules Off No loading procedure active and no configuration data exchange on the processor module Table 3: Maintenance Indicators With processor modules, these LEDs indicate that the PADT is being used and the type of action performed with the PADT. It can thus be recognized if software maintenance actions such as change, extension or test are being performed on the processor modules. 5.3 Field Termination Assemblies The field termination assemblies are maintenance free. Only if a failure occurs, the defective field termination assembly must be replaced with a one of the same type or with an approved replacement model. While a field termination assembly is being replaced, the connected sensors or actuators are not available. A part of the sensors or actuators were already disturbed due to the failure. If redundant sensors or actuators were configured for the connected sensors or actuators, the complete system operability can be ensured during replacement. This applies if the following conditions are met: - The connection between the redundant sensors or actuators and the processor module is not disturbed. - Separated field termination assemblies are used to connect the redundant sensors or actuators. If not all the sensors or actuators have been redundantly configured, take the consequences of the replacement on the entire process into account. If necessary, further technical and organizational measures must be taken to ensure that the process during replacement is sufficiently monitored in terms of safety. Refer to the manual of the corresponding field termination assembly for more details. Page 12 of 16 HI 801 171 E Rev. 1.00
Maintenance 5 Maintenance Actions, in Details 5.4 Base Plate If defective, the base plate must be replaced. The replacement may cause the system busses to other base plates to be interrupted. For this reason, prior to replacing the base plates, think about the consequences that the replacement may have on the entire process in terms of safety and availability. With this in mind, the following actions must be planned: When the replacement should be performed (point in time). Technical and organizational measures that must be taken to ensure that the process during replacement is sufficiently monitored in terms of safety. Refer to the manual of the base plate (HI 801 025 E) for more details. HI 801 171 E Rev. 1.00 Page 13 of 16
5 Maintenance Actions, in Details Maintenance Page 14 of 16 HI 801 171 E Rev. 1.00
Maintenance Appendix Appendix Index of Figures Figure 1: Mounting and Removing a Module 11 Index of Tables Table 1: Required Operating and Maintenance Activities 6 Table 2: Valid Documentation 7 Table 3: Maintenance Indicators 12 HI 801 171 E Rev. 1.00 Page 15 of 16
HI 801 171 E 2010 HIMA Paul Hildebrandt GmbH + Co KG HIMax and SILworX are registered trademark of: HIMA Paul Hildebrandt GmbH + Co KG Albert-Bassermann-Str. 28 68782 Brühl, Germany Tel. +49 6202 709-0 Fax +49 6202 709-107 HIMax-info@hima.com www.hima.com