SIGMA TEK CSDI 162 User manual

C-DIAS SAFETY DIGITAL INPUT MODULE CSDI 162
1.3 Page 1
Document changes and version status
Change date
Affected
page(s)
Changes/expansions/corrections
Version
19.12.2013
12 to 12a
Added Standard and Electrical requirements for UL table
1.1
31.01.2018
5, 8, 9, 13
8
13
14
Removed standard IEC 61508
Added amendments „Category 4“ and „EN“
Added chapter „Conformity with EU Standards”
Added amendment „EN“ (62061)
Added „Cat. 4“
Added unit 1/h on PFHDvalue
Changed value from 5.13 to 5.13E-09
Changed EMC resistance to 61000-6-2:2005
1.2
05.10.2018
11
Note cable capacitance and cable resistance added
1.3

CSDI 162 C-DIAS SAFETY DIGITAL INPUT MODULE
Page 2 05.10.2018
Contents
Directory of Illustrations...................................................................................... 3
Directory of Tables............................................................................................... 3
Explanation of Safety Symbols........................................................................... 4
Documentation Note............................................................................................ 4
Delivery Condition ............................................................................................... 4
Operator Due Diligence....................................................................................... 4
Test Signals for Cross-Circuit Detection........................................................... 5
Installation............................................................................................................ 5
General Instructions for Operating the Safety Modules .................................. 5
The C-DIAS bus and Connector Layout........................................................................6
C-DIAS Safety Digital Input Module CSDI 162............................................... 8
Module Description .......................................................................................................8
Designated Use.................................................................................................... 9
Mechanical Dimensions .................................................................................... 10
Technical Data.................................................................................................... 11
Input specifications......................................................................................................11
Specifications for the cross-circuit detection signal outputs........................................11
Electrical requirements................................................................................................12
The Safety modules' electrical supply must also be provided over the C-DIAS bus. A
different type and method of supplying energy is not allowed.....................................12
Safety Conformity.............................................................................................. 13
Conformity with EU Standards....................................................................................13
Functional safety standards ........................................................................................13
Safety-relevant parameters.........................................................................................13
Environmental conditions............................................................................................14
Miscellaneous .............................................................................................................15
CSDI 162 Circuit................................................................................................. 16

C-DIAS SAFETY DIGITAL INPUT MODULE CSDI 162
1.3 Page 3
LED Display ........................................................................................................17
Connector Layout .............................................................................................. 18
Connector Plug Coding.....................................................................................20
Error Response .................................................................................................. 22
Restart Errors ............................................................................................................. 22
Troubleshooting with the SafetyDesigner................................................................... 23
Correcting a wiring error............................................................................................. 23
Input Circuit........................................................................................................24
Practical Example of a Circuit...........................................................................25
Requirements ............................................................................................................. 25
Implementation........................................................................................................... 26
Connection Diagram................................................................................................... 27
Directory of Illustrations
Fig. 1: Example of a minimum system for a safety-related control....................................... 6
Fig. 2: CSDI 162................................................................................................................... 8
Fig. 3: Mechanical dimensions........................................................................................... 10
Fig. 4: CSDI 162 circuit....................................................................................................... 16
Fig. 5 : Connector plug coding............................................................................................ 20
Fig. 6: Simplified status diagram ........................................................................................ 22
Fig. 7: Input circuit structure............................................................................................... 24
Fig. 8: Simplified representation of the processing machine.............................................. 25
Fig. 9: Example structure diagram...................................................................................... 26
Directory of Tables
Table 1: C-DIAS bus connector layout ................................................................................. 6
Table 2: Input specifications............................................................................................... 11
Table 3: Clock output specifications................................................................................... 11
Table 4: Electrical requirements......................................................................................... 12
Table 5: Safety parameters ................................................................................................ 13
Table 6: Environmental conditions ..................................................................................... 14
Table 7: Miscellaneous....................................................................................................... 15
Table 8: LED Display.......................................................................................................... 17
Table 9: Connector layout .................................................................................................. 19
Table 10: Example schematic ............................................................................................ 27

CSDI 162 C-DIAS SAFETY DIGITAL INPUT MODULE
Page 4 05.10.2018
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 modules or the entire Safety
application, the instructions and explanations in this documentation must be followed ex-
plicitly.
Delivery Condition
The individual SIGMATEK Safety components are delivered in specific hard and software
configurations. Any change of this configuration that exceeds the options specified in this
documentation, is unauthorized 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
operation.

C-DIAS SAFETY DIGITAL INPUT MODULE CSDI 162
1.3 Page 5
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.

CSDI 162 C-DIAS SAFETY DIGITAL INPUT MODULE
Page 6 05.10.2018
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 (internal)
15
GND (internal)
15
GND (internal)
16
GND (external)
16
GND (external)
16
GND (external)
Table 1: C-DIAS bus connector layout
Fig. 1: Example of a minimum system for a safety-related control

C-DIAS SAFETY DIGITAL INPUT MODULE CSDI 162
1.3 Page 7
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.

CSDI 162 C-DIAS SAFETY DIGITAL INPUT MODULE
Page 8 05.10.2018
C-DIAS Safety Digital Input Module CSDI 162
Module Description
The Safety input component series has the Safety integri-
ty level SIL3 and/or SIL CL 3 according to (IEC 62061)
and/or Performancelevel e (PL e) / Category 4 (EN ISO
13849). The Safety-CPU component series has:
16 safe inputs (IEC/EN 61131)
Doubled clock output signal (short-circuit proof)
The Safety inputs are used for reading 16 Safety actuator
signals (emergency stop, confirmation button etc.).
The Safety input module has 2 non-Safety signal outputs,
TA and TB, to test inputs and detect cross-circuit errors
(i.e. emergency stop).
Fig. 2: CSDI 162
The Safety input module CSDI 162 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.
To use the Safety input module in an application, a Safety CPU module that regulates the
synchronized communication with the Safety modules using safe bus telegrams is also
required. This also includes
•Processing the safe application and
•The distribution of configuration data to remote Safety modules.

C-DIAS SAFETY DIGITAL INPUT MODULE CSDI 162
1.3 Page 9
Designated Use
The CSDI 162 Safety module is designed for use in Safety-related applications
and meets the required conditions for Safety operation in compliance with Perfo-
mancelevel 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 CSCP
012 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.

CSDI 162 C-DIAS SAFETY DIGITAL INPUT MODULE
Page 10 05.10.2018
Mechanical Dimensions
Fig. 3: Mechanical dimensions

C-DIAS SAFETY DIGITAL INPUT MODULE CSDI 162
1.3 Page 11
Technical Data
Input specifications
The inputs are type 1 according to IEC/EN 61131
Number of …
16
Input voltage
+24 V DC
Input voltage range
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 2: Input specifications
Specifications for the cross-circuit detection signal outputs
Number of …
2
Rated output voltage
+24 V DC
Output voltage range
Minimum +18 V
Maximum +30 V
Output current
100 mA at +24 V
Miscellaneous
Short-circuit proof
Table 3: Clock 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.

CSDI 162 C-DIAS SAFETY DIGITAL INPUT MODULE
Page 12 05.10.2018
Electrical requirements
The Safety modules' electrical supply must also be provided over the C-DIAS bus. A differ-
ent 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 4: 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 (24 V DC 16 x 5 mA)
16 x 5 mA at +24 V
Output
(General use Ampere Rating)
Cross-circuit detection signal output
a

C-DIAS SAFETY DIGITAL INPUT MODULE CSDI 162
1.3 Page 13
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
- EN/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 [%]
95.7
Probability of failure per hour
PFHD[1/h]
5.13E-09
Mean time to dangerous failure
MTTFD [years] symmetrized
472
Proof Test Interval [years]
20
Table 5: Safety parameters
Please note:
The parameters shown are only applicable with the simultaneous parallel use of
two inputs.

CSDI 162 C-DIAS SAFETY DIGITAL INPUT MODULE
Page 14 05.10.2018
Environmental conditions
Storage temperature
-20 to +85 °C
Environmental 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 6: Environmental conditions

C-DIAS SAFETY DIGITAL INPUT MODULE CSDI 162
1.3 Page 15
Miscellaneous
Article number
12-891-162
Hardware version
1.x
Table 7: Miscellaneous

CSDI 162 C-DIAS SAFETY DIGITAL INPUT MODULE
Page 16 05.10.2018
CSDI 162 Circuit
Fig. 4: CSDI 162 circuit
For the functions and LED display, see the following chapter
"LED Displays".

C-DIAS SAFETY DIGITAL INPUT MODULE CSDI 162
1.3 Page 17
LED Display
The LED display lights continuously to indicate that the in- and outputs are active.
Label
Color
Function
Display
1 –16
Green
Digital inputs 1 –16
(connector X1, X2, X3, X4)
Fast blinking frequency (wiring error, cross circuit... )
DC
Green
DCOK +24 V
Indicates that the +24 V supply for the clock signals is
within the defined limits.
RN
Green
RUN
Indicates the time-unlimited (LED "ST" off) operational
mode
ST
Yellow
Status
-Lights permanently: The module is current-
ly in service mode
-Slow blinking frequency: The module is in
the Idle or Check configuration (because
the mode transition can be very fast, the
blinking signal is normal not noticed.
E
Red
Error
-Lights permanently: the module is in error
mode
-Fast blinking frequency: Serious error;
communication with the module is no
longer possible (CANNOT be read with the
SafetyDesigner
Table 8: LED Display

CSDI 162 C-DIAS SAFETY DIGITAL INPUT MODULE
Page 18 05.10.2018
Connector Layout
Module connection
Label
Pin
Function
Connection
X1: digital inputs (Group G1)
X2: digital inputs (Group G2)
X3: digital inputs (Group G3)
X4: digital inputs (Group G4)
DI1
X1 / 1
Digital Input 1
DI2
X1 / 2
Digital Input 2
DI3
X1 / 3
Digital Input 3
DI4
X1 / 4
Digital Input 4
DI5
X2 / 1
Digital Input 5
DI6
X2 / 2
Digital Input 6
DI7
X2 / 3
Digital Input 7
DI8
X2 / 4
Digital Input 8
DI9
X3 / 1
Digital Input 9
DI10
X3 / 2
Digital Input 10
DI11
X3 / 3
Digital Input 11
DI12
X3 / 4
Digital Input 12
DI13
X4 / 1
Digital Input 13
DI14
X4 / 2
Digital Input 14
DI15
X4 / 3
Digital Input 15
DI16
X4 / 4
Digital Input 16

C-DIAS SAFETY DIGITAL INPUT MODULE CSDI 162
1.3 Page 19
X5: clock signal outputs
Table 9: Connector layout
The complete C-DIAS connector set (5 connector plugs with spring terminals;
Phoenix Contact: FK-MCP 1,5/ 4-ST-3.5) is included in delivery of the C-DIAS
module.
A
X5 / 1
Clock Output A
B
X5 / 2
Clock Output B
+
X5 / 3
+24 V
(supply for clock signal
output)
-
X5 / 4
GND

CSDI 162 C-DIAS SAFETY DIGITAL INPUT MODULE
Page 20 05.10.2018
Connector Plug Coding
Fig. 5 : Connector plug coding
Plug X4
Plug X3
Plug X2
Plug X1
Socket X4
Coding pin 4 (Pin 4)
Socket X3
Coding pin 3 (Pin 3)
Socket X2
Coding pin 2 (Pin 2)
Socket X1
Coding
pin 1
(Pin 1)