SIGMA TEK C-DIAS CSCP 012 User manual

C-DIAS SAFETY CPU CSCP 012
1.6 Page 1
Document changes and version status
Change date
Affected
page(s)
Changes/expansions/corrections
Version
19.12.2013
14
Added Standard and Electrical requirements for UL table
1.1
17.02.2016
12
Switching-off inductive loads
1.2
15.05.2017
13
Specifications of maximum allowable output loads refined
1.3
04.12.2017
6, 9, 10, 16
16
17
Removed standard IEC 61508
Added chapter „Conformity with EU Standards“
Added „Cat. 4“
Added unit 1/h on PFHDvalue
Changed value from 5.81 to 5.8E-09
Changed EMC resistance standard to 61000-6-2:2005
1.4
31.01.2018
9
Note Safety outputs protected polarity changed
1.5
05.10.2018
14
Note cable capacitance and cable resistance added
1.6

CSCP 012 C-DIAS SAFETY CPU
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Contents
List of Illustrations............................................................................................... 4
List of Tables........................................................................................................ 4
Explanation of Safety Symbols........................................................................... 5
Documentation Note............................................................................................ 5
Delivery Condition ............................................................................................... 5
Operator Due Diligence....................................................................................... 5
Test signals for Cross-Circuit Detection........................................................... 6
Installation............................................................................................................ 6
General Instructions for Operating the Safety Modules .................................. 6
The C-DIAS bus and Connector Layout........................................................................7
C-DIAS Safety CPU CSCP 012......................................................................... 9
Module Description.............................................................................................. 9
Designated Use.................................................................................................. 10
Mechanical Dimensions .................................................................................... 11
Technical Data.................................................................................................... 12
Output specifications...................................................................................................12
Maximum inductive load L (mH) at load current I (A)..................................................13
Maximum capacitive load C (µF) at load current I (A).................................................13
Input specifications......................................................................................................14
Specifications for the cross-circuit detection signal outputs........................................14
Electrical requirements................................................................................................15
Safety Conformity.............................................................................................. 16
Conformity with EU Standards ....................................................................................16
Functional safety standards ........................................................................................16
Safety-relevant parameters.........................................................................................16
Environmental conditions............................................................................................17
Miscellaneous .............................................................................................................17

C-DIAS SAFETY CPU CSCP 012
1.6 Page 3
Output Power Supply......................................................................................... 17
CSCP 012 Circuit................................................................................................18
LED Display ........................................................................................................19
Connector Layout ..............................................................................................20
Connector Plug Coding.....................................................................................21
Validation Button ............................................................................................... 22
Explanation of the individual sequences .................................................................... 22
Overview of Commands ............................................................................................. 24
Handling the micro SD Card .............................................................................26
Configuring a Safety CPU with the SD card ............................................................... 26
Error Response ..................................................................................................28
Restart Errors ............................................................................................................. 28
Configuration distribution error ................................................................................... 29
Troubleshooting.......................................................................................................... 30
Troubleshooting with the SafetyDesigner................................................................... 30
Correcting a wiring error............................................................................................. 30
Input Circuit........................................................................................................31
Output Circuit.....................................................................................................31
Practical Example of a Circuit........................................................................... 32
Requirements ............................................................................................................. 32
Implementation........................................................................................................... 33
Connection Diagram................................................................................................... 35

CSCP 012 C-DIAS SAFETY CPU
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List of Illustrations
Fig. 1: Minimal system of safety-related control....................................................................7
Fig. 2: CSCP 012 ..................................................................................................................9
Fig. 3: Mechanical dimensions............................................................................................11
Fig. 4: Inductive load...........................................................................................................13
Fig. 5: Capacitive load.........................................................................................................13
Fig. 6: CSCP 012 circuit......................................................................................................18
Fig. 7: Connector plug coding.............................................................................................21
Fig. 8: Command sequences..............................................................................................22
Fig. 9: Simplified status diagram.........................................................................................28
Fig. 10: Input circuit structure..............................................................................................31
Fig. 11: Output circuit structure...........................................................................................31
Fig. 12: Simplified representation of the processing machine ............................................32
Fig. 13: Example structure diagram ....................................................................................34
List of Tables
Table 1: C-DIAS bus connector layout..................................................................................7
Table 2: Output specifications.............................................................................................12
Table 3: Allowable output loads ..........................................................................................13
Table 4: Input specifications................................................................................................14
Table 5: Signal output specifications...................................................................................14
Table 6: Electrical requirements..........................................................................................15
Table 7: Safety-relevant parameters...................................................................................16
Table 8: Environmental conditions......................................................................................17
Table 9: LED Display ..........................................................................................................19
Table 10: Connector layout.................................................................................................20
Table 11: Overview of commands.......................................................................................24
Table 12: Module status overview.......................................................................................24
Table 13: Status transitions.................................................................................................25
Table 14: Connection diagram example .............................................................................35

C-DIAS SAFETY CPU CSCP 012
1.6 Page 5
Explanation of Safety Symbols
This symbol identifies important or additional information in relation to the opera-
tion of the individual components.
This symbol identifies danger for personnel, the environment or equipment. If
safety instructions are not observed, it can result in environmental or equipment
damage and/or pose a danger to the life and health of personnel.
Documentation Note
This documentation is intended exclusively for trained personnel in control and automation
technology. For installation and the initial start-up of individual module or the entire Safety
application, the instruction and explanations in this documentation and the Safety System
handbook must be followed explicitly.
Delivery Condition
The individual SIGMATEK Safety components are delivered in specific hard and software
configurations. Any change of this configuration, which exceeds the options specified in
this documentation, is not authorized and invalidates the warranty from SIGMATEK GmbH
& Co KG.
Operator Due Diligence
The operator must ensure that
•the components are used for their designated purpose only.
•the components are operated in error-free, fully functional condition only.
•only sufficiently qualified and authorized personnel operate the components.
•the documentation is complete and in readable condition and available at the site of op-
eration.

CSCP 012 C-DIAS SAFETY CPU
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Test signals for Cross-Circuit Detection
The module sends pulses in cyclic time intervals to detect a crossed circuit in the
outputs. When selecting the actuators, keep in mind that these pulses do not acti-
vate the actuators or trigger any diagnostic messages. The pulse signals cannot
be deactivated or configured.
Cross-Circuit Detection
Please keep in mind that the cross-circuit detection only functions correctly when
it is correctly wired and configured. This applies equally to in- and outputs.
Installation
Before assembling, disassembling or wiring the module, put the entire system in a safe,
voltage-free condition. The module must be mounted in a control cabinet or terminal box
for operation.
General Instructions for Operating the Safety Modules
In the Safety System handbook, the following topics to be observed are covered:
•System requirements
•Performance level e according to EN ISO 13849 and/or SIL 3 according to EN
62061
•Safety guidelines
•EMVG
•Function and operation
•Wiring
To power the Safety modules correctly, the C-DIAS bus must be used (see below). The
construction and structure are shown in the following illustration.
The appropriate module carriers for the C-DIAS bus are, for example, CMB 021/041/081
with 2, 4 or 8 slots for C-DIAS modules respectively. The important thing is that the slot
framed in red shown in the picture is intended for a PLC or coupler module.
A C-DIAS IPC (Compact DIAS Industrial PC) is typically used as the PLC, while for exam-
ple, a CIV 512 can be used as the coupler module. In the latter however, a connection to a
PLC over the VARAN bus is required.

C-DIAS SAFETY CPU CSCP 012
1.6 Page 7
The C-DIAS bus and Connector Layout
A
Signal
B
Signal
C
Signal
1
CDIAS_/MS
1
CDIAS_/RES
1
------
2
CDIAS_EE_A2
2
CDIAS_EE_CLK
2
CDIAS_EE_DAT
3
CDIAS_EE_A1
3
CDIAS_SYNC
3
CDIAS_EE_IRQ
4
CDIAS_EE_A0
4
CDIAS_RDY
4
CDIAS_/DEN
5
------
5
CDIAS_/RD
5
CDIAS_/WR
6
------
6
CDIAS_A6
6
CDIAS_A7
7
------
7
CDIAS_A4
7
CDIAS_A5
8
------
8
CDIAS_A2
8
CDIAS_A3
9
------
9
CDIAS_A0
9
CDIAS_A1
10
------
10
CDIAS_D6
10
CDIAS_D7
11
------
11
CDIAS_D4
11
CDIAS_D5
12
------
12
CDIAS_D2
12
CDIAS_D3
13
+24V_CDIAS
13
CDIAS_D0
13
CDIAS_D1
14
+5V_UNFUSED
14
+5V_UNFUSED
14
+5V_UNFUSED
15
GND (intern)
15
GND (intern)
15
GND (intern)
16
GND (extern)
16
GND (extern)
16
GND (extern)
Table 1: C-DIAS bus connector layout
Fig. 1: Minimal system of safety-related control

CSCP 012 C-DIAS SAFETY CPU
Page 8 05.10.2018
The minimal system of a safety-related control, formed as shown above, with a C-IPC a
CMB 081 and a Safety CPU type CSCP 012.
The safety-related application is found in the Safety CPU and can run independently of the
C-IPC. The C-IPC, however, is required to power the bus correctly and cannot be removed.
In addition, it is also needed to establish the communication between the Safety CPU and
the design tool (SafetyDesigner).
On the C-IPC and coupler modules, connectors are provided over which the C-DIAS bus
must be externally supplied with a voltage of 24 V. The external supply for the output and
clock drivers should be independent of the external C-DIAS bus supply (see below).
With the help from an SD card with a valid configuration, the Safety CPU can also be con-
figured independently of the design tool (SafetyDesigner). More information hereto can be
found in the chapter "Handling the micro SD card". With regard to the configuration using
the design tool, the SafetyDesign handbook must be consulted.
The Safety CPU is delivered without a password. The user must set a password in the
Safety CPU.

C-DIAS SAFETY CPU CSCP 012
1.6 Page 9
C-DIAS Safety CPU CSCP 012
Module Description
The Safety CPU component series has the safety integrity
level SIL3 and/or SIL CL 3 according to IEC 62061 and/or
Performance level e (PL e) according to EN ISO 13849.
The Safety CPU component series has:
4 safe inputs (IEC/EN 61131)
2 safe outputs (IEC/EN 61131)
The safety in- and outputs are used for the safety-related
reading of 4 input channels or 2 double-channel sensor
signals (emergency stop, confirmation button etc.) and the
safety-related output of 2 actuator signals to, for example,
control relays, valve, etc.
Fig. 2: CSCP 012
The Safety CPU module CSCP 012 is suited for use in systems with optional modules and
interface variables in accordance with the system hand book version 1.5, sections 1.6, 7.1
and 7.2.
The Safety CPU module has 2 non-safety signal outputs, TA and TB, to test inputs and
detect cross-circuit faults (i.e. emergency stop).
The CPU module alone is already a minimal system of a safety control. A practical exam-
ple is given later in this handbook.
In addition, the Safety CPU regulates the synchronized communication with the remote
Safety modules through safe bus telegrams. Among their jobs are:
•Processing the safe application and
•The distribution of configuration data to remote Safety modules.
When wiring, it is important to note that the output supply of the Safety outputs is
not protected against polarity reversal.
If the polarity wired in reverse, the Safety module must be exchanged and sent for
repair.

CSCP 012 C-DIAS SAFETY CPU
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Designated Use
The CSCP 012 Safety module is designed for use in safety-related applications
and meets the required conditions for safety operation in compliance with Perfor-
mance level e (PL e), according to EN ISO 13849 and/or SIL 3 according to EN
62061. It is usually used in conjunction with other Safety modules such as CSDI
162 and CSTO 082, for example.
Installation, mounting, programming, initial start-up, operation, maintenance and
discarding of Safety modules can only be performed by qualified personnel.
Qualified personnel in this context are people, who have completed training or
have been trained under supervision of qualified personnel and have been author-
ized to operate and maintain safety-related equipment, systems and facilities in
compliance with the strict guidelines and standards of safety technology. More in-
formation on Standards etc. can be found in the Safety System Handbook.
For your own safety and the safety of others, use Safety modules for their desig-
nated purpose. Correct EMV installation is also included in the designated use.
Non-designated use consists of
•Any change made to the Safety modules of any kind.
•The use of damaged Safety modules.
•The use of the Safety module outside of the instructions described in this
handbook.
•The use of the Safety module outside of the technical data described in this
handbook.

C-DIAS SAFETY CPU CSCP 012
1.6 Page 11
Mechanical Dimensions
Fig. 3: Mechanical dimensions

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Technical Data
Output specifications
All safety outputs are short-circuit protected and specified according to IEC/EN 61131. The
outputs are compatible with input of type 1, 2 and 3.
Number of …
2
Rated output voltage
+24 V DC
Output voltage range
minimum +18 V
maximum +30 V
Maximum output current
2 A
Maximum total current per
output group (2 outputs)
2 A
Brake voltage with switching-off
inductive loads
typically 0.85 V
Maximum switch-off energy of
the outputs (inductive load)
maximum 0.4 Joule per channel
Turn-on delay
< 200 µs
Turn-off delay
< 1 ms
Miscellaneous
short-circuit proof
Cut-off test signal
< 1.5 ms
Table 2: Output specifications

C-DIAS SAFETY CPU CSCP 012
1.6 Page 13
Maximum inductive load L (mH) at load current I (A)
Fig. 4: Inductive load
Maximum capacitive load C (µF) at load current I (A)
Fig. 5: Capacitive load
I (A)
L (mH)
C (µF)
0
6400
1.25
0.5
1600
3.13
1
400
5
2
100
8.75
Table 3: Allowable output loads

CSCP 012 C-DIAS SAFETY CPU
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Input specifications
The inputs are type 1 according to IEC/EN 61131
Number of …
4
Input voltage
+24 V DC
Input voltage range including
ripple
Minimum +18 V
Maximum +30 V
Signal level
Low: ≤ +5 V
High: ≥ +15 V
Switching threshold
Typically +11 V
Input current
5 mA at +24 V
Input delay
Maximum 2.5 ms
Table 4: Input specifications
Specifications for the cross-circuit detection signal outputs
Number of …
2
Rated output voltage
+24 V DC
Output voltage range including
ripple
Minimum +18 V
Maximum +30 V
Output current
100 mA at +24 V
Miscellaneous
Short-circuit proof
Table 5: Signal output specifications
When using the digital inputs with the clock outputs for cross-wire detection for long
cable lengths, it must be ensured that the cable capacitance from the clock output to
the digital input does not exceed a value of 75 nF in relation to GND and that the
cable resistance does not exceed a value of 250 Ω, so that the cross-wire detection
does not detect a wiring fault if the wiring is correct.

C-DIAS SAFETY CPU CSCP 012
1.6 Page 15
Electrical requirements
The Safety modules' electrical supply must also be provided over the C-DIAS bus in a
stand-alone system. A different type and method of supplying energy is not allowed.
The C-DIAS bus system's external 24 V supply voltage must be generated by a PELV
power supply.
Rated supply voltage
+24 V DC (C-DIAS bus)
Supply voltage range including
ripple
Minimum +18 V
Maximum +30 V
Voltage supply from C-DIAS bus
+5 V
Current consumption of C-DIAS
bus (+5 V supply)
Typically 50 mA
Current consumption of C-DIAS
bus (+24 V supply)
Typically 90 mA
Maximum interrupt time for volt-
age interruptions
10 ms
Standard
UL 508 (E247993)
Table 6: Electrical requirements
Electrical requirements for UL
IMPORTANT:
The device was tested in accordance with the UL 508 Norm as a low voltage limited power
circuit (LVLC - limited voltage/limited current). To meet the standard requirements, the
device must be powered by a galvanically isolated source (+24 V DC), which is protected
with a UL-certified 4 A fuse (UL 248) in the secondary circuit. If the device is powered by
two galvanically isolated sources, one to power the electronics and one for the frequency
output, each source must be equipped with a UL-certified 4 A fuse (UL 248) in the second-
ary circuit.
Input
18 - 30 V DC
4 x 5 mA at +24 V
Output
(General use Ampere Rating)
18 - 30 V DC
2 A per channel,
maximum 2 A complete module
a

CSCP 012 C-DIAS SAFETY CPU
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Safety Conformity
Conformity with EU Standards
The module has been designed in accordance with the following European Union direc-
tives:
2006/42/EG Machinery Directive
2014/30/EU EMC Directive
2011/65/EU RoHS Directive
Functional safety standards
- IEC 62061 SIL 3 or SIL CL 3
- EN ISO 13849 PL e / Cat. 4
Configuration: 2-channel redundant (diverse)
Safety-relevant parameters
Diagnostic coverage
DC [%]
96
Probability of failure per hour
PFHD[1/h]
5.8E-09
Mean time to dangerous failure
MTTFD symmetrized [years]
424
Proof Test Interval [years]
20
Table 7: Safety-relevant parameters
Please note:
The parameters shown are only applicable with the simultaneous parallel
use of two inputs.

C-DIAS SAFETY CPU CSCP 012
1.6 Page 17
Environmental conditions
Storage temperature
-20 to +85 °C
Operating temperature
0 to +55 °C
Humidity
0 to 95 %, uncondensed
EMV stability
According to EN 61000-6-2: 2005 (industrial area) Raised requirements
according to IEC 26061
Shock resistance
EN 60068-2-27
15 g
Protection Type
EN 60529
IP 20
Table 8: Environmental conditions
Miscellaneous
Article number
12-890-012
Hardware version
1.x
Output Power Supply
So that a short circuit on the supply of the outputs resulting from an error does not
cause the PLC to fail, it is recommended that separate power supplies be used for
the 24 V C-DIAS bus supply (fed to the C-IPC or CIV) and the supply for the out-
puts and clock signals.

CSCP 012 C-DIAS SAFETY CPU
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CSCP 012 Circuit
Fig. 6: CSCP 012 circuit
For the functions and LED display, see the
following chapter "LED Displays".

C-DIAS SAFETY CPU CSCP 012
1.6 Page 19
LED Display
The LED display lights continuously to indicate that the in- and outputs are active.
Label
Color
Function
Display
1 –4
Green
Digital inputs 1 –4
(connector X2)
Fast blinking frequency (wiring error, cross circuit... )
5 –6
Yellow
Digital outputs 1 –2
(connector X1)
Fast blinking frequency (wiring error, cross circuit... )
B
Red
Display validation button S1
See chapter "Validation Button" for description
DC
Green
DCOK +24 V
Signals that the +24 V supply for outputs and clocks
are within the defined limits.
RN
Green
RUN
Indicates
-
- The time-limited (LED "ST" on) and/or
- The time-unlimited (LED "ST" off) opera-
tion mode
ST
Yellow
Status
-Lights permanently: the module is currently
in service mode
-Slow blinking frequency: the module is cur-
rently in Idle or Check Configuration mode
E
Red
Error
-Lights permanently: the module is in error
mode
-Slow blinking frequency: the maximum age
has been exceeded for a removed input
(can be read with the SafetyDesigner)
-Fast blinking frequency: serious error;
communication with the module is no
longer possible (CANNOT be read with the
SafetyDesigner
C1
Yellow
Command 1
See chapter "Validation Button" for description
C2
Yellow
Command 2
See chapter "Validation Button" for description
C3
Yellow
Command 3
See chapter "Validation Button" for description
Table 9: LED Display

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Connector Layout
Module connection
Label
Pin
Function
Connector
X1: digital outputs and voltage supply (Group G1)
X2: digital inputs
X3: clock output and supply voltage
Table 10: Connector layout
The complete C-DIAS connector set (3 connector plugs with spring terminals;
Phoenix Contact: FK-MCP 1,5/ 4-ST-3.5) is included in delivery of the C-DIAS
module.
TO1
X1 / 1
Digital output 1
TO2
X1 / 2
Digital output 2
+
X1 / 3
+24 V (output supply)
-
X1 / 4
GND
DI1
X2 / 1
Digital input 1
DI2
X2 / 2
Digital input 2
DI3
X2 / 3
Digital input 3
DI4
X2 / 4
Digital input 4
A
X3 / 1
Output A
B
X3 / 2
Clock output B
+
X3 / 3
+24 V
(supply for clock signal
output)
-
X3 / 4
GND