HIMA Z7128

Description

Product Description

The HIMA Z7128 is a specialized high-speed pulse counting and frequency monitoring module for HIMA’s highly reliable safety systems, such as the HIMax or HIMatrix platforms. This module is engineered for safety-critical applications where the accurate monitoring of rotational speed or the counting of rapid pulses is essential for protective functions. Its primary function is to interface with sensors like magnetic pickups (MPUs) or proximity probes mounted on rotating equipment (e.g., turbines, pumps, compressors) to measure shaft speed or detect overspeed conditions. The HIMA Z7128 conditions the raw pulse signal, validates its integrity, and provides a precise frequency or speed value to the safety controller’s logic solver. Designed with the high diagnostic coverage required for Safety Instrumented Systems (SIS), this module is capable of detecting faults within itself and in the sensor loop. Implementing the HIMA Z7128 is critical for applications such as turbine overspeed protection, where its fast and reliable response is non-negotiable for preventing catastrophic mechanical failure.

Product Parameters

• System Family: HIMA HIMax or HIMatrix Safety System.
• Module Type: Pulse Input / Frequency Monitoring Module (Safety-rated).
• Input Channels: Typically 2 or 4 channels for redundant or diverse speed sensing.
• Input Signal: Accepts pulsed signals from passive sensors (e.g., magnetic pickups) or active proximity sensors. Configurable for various voltage levels and pulse shapes.
• Frequency Range: Designed to accurately measure a wide range of pulse frequencies corresponding to equipment speeds from very low RPM to high RPM.
• Safety Certification: Certified for use in Safety Instrumented Systems up to SIL 2 or SIL 3 according to IEC 61508/61511.
• Diagnostics: Extensive built-in diagnostics for sensor health (open wire, short circuit), signal validity (pulse shape, frequency limits), and module hardware faults.
• Voting Logic: Often supports internal voting (e.g., 1oo2, 2oo3) on redundant input channels before presenting a validated speed value.
• Communication: Provides validated speed data and status to the safety CPU via the internal safety network.
• Status Indicators: Comprehensive LED indicators for power, channel status, and faults.

Advantages and Features

• Safety-Certified for Critical Protection: Unlike standard pulse counters, the HIMA Z7128 is designed and certified specifically for safety functions, with a focus on detecting dangerous failures to ensure a safe state.
• Advanced Signal Validation: Not only counts pulses but also analyzes signal quality (amplitude, shape) to reject noise or faulty sensor signals, preventing spurious trips or dangerous failures to trip.
• Redundant Channel Support: Built to handle multiple sensor inputs for the same measurement point, enabling architectures that enhance both safety availability and integrity.
• Deterministic and Fast Response: Provides predictable processing times essential for timely execution of safety functions like overspeed protection, where milliseconds matter.
• Seamless Safety System Integration: Fully integrated into the HIMA safety engineering environment (e.g., Safety Manager), allowing for transparent configuration, online monitoring, and diagnostic reporting.

Application Cases in Application Fields

• Gas & Steam Turbine Overspeed Protection: The primary module for receiving and validating signals from multiple independent speed probes on a turbine shaft.
• Compressor and Pump Anti-Surge/Speed Monitoring: Monitors shaft speed for critical machinery protection schemes and permissive interlocks.
• Conveyor or Mill Overspeed Protection: Provides safety-rated speed monitoring for large mechanical drives to prevent damage from over-speed conditions.
• Marine Propulsion Safety Systems: Monitors the speed of main engines and propulsion shafts for safety interlocks.

Comparisons with Competing Products

• Vs. Standard PLC High-Speed Counter Cards (e.g., Siemens FM350): Standard cards count pulses but lack the comprehensive signal validation, internal voting, high diagnostic coverage, and functional safety certifications required for safety-related protection. They are for measurement, not for safety instrumented functions.
• Vs. Dedicated Overspeed Trip Devices (e.g., Woodward or Bentley Nevada): These are standalone hardware trip devices. The HIMA Z7128 integrates speed sensing into the broader, programmable safety system, allowing for more complex trip logic involving other process variables and centralized diagnostics.
• Vs. Other Safety System Pulse Modules (e.g., Triconex): Competing safety systems have equivalent modules. The differentiation lies in the system architecture (HIMA’s dedicated safety controllers vs. TMR), diagnostic methods, and engineering toolset.

Selection Suggestions and Precautions

1. Safety Lifecycle Compliance: The HIMA Z7128 must be selected as part of a full Safety Lifecycle according to IEC 61511, including SIL verification and PFDavg calculations.
2. Sensor Compatibility and Configuration: Meticulously match the sensor type, voltage, and minimum/maximum frequency to the module’s configurable input parameters. Incorrect configuration can lead to signal rejection or undetected dangerous failures.
3. Redundant Sensing Strategy: Follow defined safety architectures (e.g., 2oo3 voting for overspeed). This dictates how many HIMA Z7128 input channels and separate sensors are required.
4. Wiring and Shielding: Use double-shielded, twisted-pair cable for sensor connections. Follow manufacturer guidelines strictly for grounding shields at one end only to prevent ground loops while maintaining noise immunity.
5. Expert Engineering Required: Configuration of the HIMA Z7128 and the associated safety logic requires specialized functional safety engineering knowledge and access to HIMA’s proprietary engineering software.

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