Description

HIMA H4135 992413502

I. Basic Information

Model: H4135 | Order Code: 992413502

Product Overview: Compact all-in-one SIL3 safety controller (PLC-style safety CPU) from Germany HIMA HIMatrix series. It integrates onboard I/O, safety logic processing and multi-channel communication interfaces, and is designed for standalone DIN rail mounting. Serving as an integrated master unit for compact SIS/ESD/F&G fire and gas systems without requiring additional mounting racks, it is a critical OEM spare part for on-site safety control of small chemical plants, skid-mounted equipment and boiler BMS applications.

Brand: HIMA | Origin: Germany

Supporting Software: HIWORX programming & configuration software, compatible with upper-level SCADA across full HIMA product range. Derivative model H4135A (Part No.992413560) is a simplified safety relay variant within the same product line.

Mounting Specification: Standard snap-on installation on 35mm DIN rail; Overall dimensions: 110(H)×90(D)×45(W) mm, Net Weight ≈0.28kg. Equipped with grey flame-retardant plastic housing; PCB coated with Grade G3 triple-protection conformal coating, IP20 ingress protection. Certifications include TÜV Rheinland, CE, UL and ATEX for Zone 2 hazardous locations.

Integrated Hardware: All-in-one onboard DI/DO/AI channels, dual Ethernet ports, RS485 and CAN bus terminals, RUN/FAULT LED status indicators and front-side terminal block.

II. Technical Specifications

(1) Safety Architecture Parameters

Safety Certifications: IEC61508 SIL3, ISO13849 PL e, EN954-1 Category 4 safety rating. Adopts internal Triple Modular Redundancy (TMR) triple-CPU fault-tolerant architecture. Three independent CPUs run calculations synchronously with voting logic; failure of a single CPU will not compromise safety interlock outputs.

System Scan Cycle: Minimum basic cycle ≥10ms, enabling millisecond-level response of safety logic for rapid emergency shutdown interlocks.

Fault Diagnosis: Real-time hardware self-test for open-circuit, short-circuit and wire-break faults on all channels; safety outputs get locked upon fault with local LED indication.

(2) Onboard Integrated I/O Specifications

Digital Input (DI): 16 channels, DC24V Type3 intrinsically safe input; rated per-channel input ≤10mA with wire-break detection.
Digital Output (DO): 12-channel fail-safe transistor output, DC24V, 0.5A per-channel load; de-energized trip on low level with independent short-circuit protection for each output.
Analog Input (AI): 4 universal channels supporting 4~20mA / 0~10VDC, 12-bit high-precision AD conversion with transmitter loop break detection.

(3) Power Supply Specifications

Input Power: DC24V (wide tolerance range:18~28.8VDC, ±20% deviation allowed); total power consumption ≤12W. Built-in reverse-polarity prevention, surge suppression and Level 4 EMC filtering; galvanic isolation ≥2000VAC between I/O circuits and internal control core.

(4) Communication Specifications

Dual 10/100Mbps auto-adaptive Ethernet: Modbus TCP, Profinet for connection to upper DCS/SCADA systems;
RS485 interface: Modbus RTU for remote field instrument communication;
CAN bus: Proprietary HIMA internal safety bus for expansion of remote I/O slave stations.

(5) Environmental Specifications

Operating Temperature: -20℃ ~ +70℃; Storage Temperature: -40℃ ~ +85℃.

Ambient Humidity: 5%~95% RH non-condensing; compliant with IEC61000 Level4 EMC immunity to resist interference from chemical dust, corrosive gas and variable-frequency drive electromagnetic radiation.

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III. Key Features

All-In-One Rack-Free Construction

Single-module integration of CPU, AI, DI and DO, directly installed inside control cabinets via DIN rail. Eliminates costly dedicated system racks for compact skid-mounted units to save cabinet space and overall project costs significantly.

TMR Triple-Redundant SIL3 Safety Core

Hardware voting across three independent processors ensures reliable actuation of safety circuits even if one single channel fails, complying with regulatory safety requirements for ESD emergency shutdown and fire & gas interlock applications.

Full-Circuit Channel Fault Self-Diagnosis

Real-time detection of DI open wiring, DO short-circuit and AI transmitter line breakage. Fault triggers local LED alert plus fault data upload to DCS via communication for convenient maintenance troubleshooting.

Multi-Protocol Interoperable Communication

Triple communication links including redundant dual-Ethernet, RS485 and CAN bus enable flexible bidirectional data exchange with mainstream DCS brands such as Yokogawa, Honeywell and ABB.

Online Program Download & Runtime Monitoring

Remote online logic modification and fault diagnosis via HIWORX software without equipment shutdown or module disassembly.

IV. Operating Principle

DC24V power supply feeds the unit → Internal power module stabilizes voltage to power three TMR control cores and all onboard I/O circuits.

Upstream Data Acquisition: Field 4~20mA temperature/pressure AI signals and valve position DI signals → Sampled by onboard I/O → Synchronous calculation and cross-verification among three CPUs.

Downstream Interlock Execution: When process parameters exceed safety thresholds → CPUs issue interlock commands → Fail-safe DO de-energizes to cut off field emergency shutdown valves and equipment trip coils.

Fault Handling Logic: In case of single CPU or single-channel hardware failure → TMR voting logic isolates the faulty channel while the remaining two channels sustain normal interlock operation; front-panel fault LED illuminates and fault information is transmitted to upper DCS.

V. Application Scenarios

Fine Chemical & Skid-Mounted Facilities: SIS interlock for small reactors and ESD emergency shutdown of skid-mounted hydrogenation units;
Oil & Gas Industry: Local F&G fire & gas systems for small gas filling stations and well sites, plus safety interlock for pressure regulating stations;
Cogeneration & Boiler Industry: BMS burner safety control for medium & small gas-fired boilers and flame-out interlock for waste heat boilers;
Machinery & Metallurgy: Emergency stop safety control systems for complete production lines;
Retrofit Spare Parts: Drop-in replacement for legacy compact HIMA safety systems and OEM spare for on-site local SIS renovation projects.