SIGMA TEK SAI 041 User manual

SAI 041
S-DIAS Safety
Analog Input Current Module
Operating Manual
Date of creation: 28.04.2022
Version date: 18.05.2022
Article number: 20-896-041-E

Publisher: SIGMATEK GmbH & Co KG
A-5112 Lamprechtshausen
Tel.: [phone]
Fax: [phone]
Email: [email protected]
WWW.SIGMATEK-AUTOMATION.COM
Copyright © 2022
SIGMATEK GmbH & Co KG
Translation from German
All rights reserved. No part of this work may be reproduced, edited using an electronic system, duplicated or
distributed in any form (print, photocopy, microfilm or in any other process) without express permission.
We reserve the right to make changes in the content without notice. SIGMATEK GmbH & Co KG is not responsible for
technical or printing errors in this handbook and assumes no responsibility for damages that occur through its use.

SAFETY ANALOG INPUT CURRENT MODULE SAI 041
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S-DIAS Safety Analog-Input Current Module SAI 041
The S-DIAS safety analog input module provides the values of
four analog current inputs from the Safe CPU (Safety CPU). The
analog inputs can also be read by the functional control CPU via
the S-DIAS bus from the safety CPU. The four current inputs
have an input range of 4-20 mA with a resolution of 16 bits. A 24
V sensor supply is provided for the analog inputs, which must be
powered externally. The external 24 V supply for the analog
inputs is monitored for Over- and under voltage.
Safe evaluation of the analog inputs is ensured by two
independent diversitary evaluations with mutual monitoring.
The safety functions of the component meet the requirements
•for two-channel use
according to SIL 3 in compliance with EN 62061 and PL e,Cat. 4 in accordance with
EN ISO 13849-1/-2.
as well as
•for single-channel use,
the requirements for to SIL 3 in compliance with EN 62061 and PL e,Cat. 3 in
accordance with EN ISO 13849-1/-2.
Date of creation: 25.06.2019
Version date: 25.06.2019
Article number: 20-890-xxx-E

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Table of Contents
1Basic Safety Guidelines......................................................... 4
1.1 General Information on Safety ....................................................4
1.2 Further Safety Guidelines............................................................5
1.3 General Requirements .................................................................6
2Safety Conformity................................................................... 8
2.1 Functional Safety Standards.......................................................8
2.2 EU Conformity Declaration..........................................................8
2.3 Safety-Relevant Parameters........................................................9
2.3.1 Horizontal Mounting position 0-60° C Environmental Temperature.....9
2.4 Compatibility.................................................................................9
3Technical Data .......................................................................10
3.1 Analog Input Specifications ......................................................10
3.2 Measurement Range...................................................................11
3.3 Electrical Requirements.............................................................11
3.4 Miscellaneous .............................................................................14
3.5 Environmental Conditions.........................................................14
4Mechanical Dimensions........................................................15
5Connector Layout..................................................................16
5.1 Status LEDs.................................................................................17
5.2 Applicable Connectors...............................................................18
5.3 Label Field...................................................................................18

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6Wiring.....................................................................................19
6.1 Wiring Example 1 SIL 3 Sensor.................................................19
6.2 Connection Example: 2 SIL 2 Sensors .....................................20
6.3 Connecting a 2-Wire Sensor......................................................21
6.4 Connecting a 3-wire Sensor ......................................................21
6.5 Connecting a 4-Wire Sensor......................................................22
6.6 Wiring Example Terminating Open Inputs...............................22
6.7 Note..............................................................................................23
7Reaction Times......................................................................23
8Mounting................................................................................24
9Transport/Storage.................................................................26
10 Storage...................................................................................26
11 Maintenance...........................................................................27
11.1 Maintenance ................................................................................27
11.2 Repair...........................................................................................27
12 Disposal .................................................................................28

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1 Basic Safety Guidelines
1.1 General Information on Safety
If the Safety guidelines are not followed, danger to personnel can result, which could then
lead to serious injury or in worst cases, death. In less serious cases, systems and equipment
can be damaged.
The following symbols identify the individual risks as well as the degree of seriousness; their
respective meanings are briefly explained below. You should therefore familiarize yourself
with the Safety symbols and their meanings to prevent dangers and risks.
DANGER
DANGER
Identifies an immediate danger with high risk, which
will lead to immediate death or serious injury if not
avoided.
Identifie un danger immédiat à haut risque, qui
entraînera immédiatement la mort ou des blessures
graves s'il n'est pas évité.
WARNING
WARNING
Identifies a possible danger with a mid-level risk, which
can lead to death or (serious) injury if not avoided.
Indique un danger possible d’un risque moyen de
décès ou de (graves) blessures si les consignes de
sécurité ne sont pas respectées.
CAUTION
CAUTION
Identifies a low-risk danger, which can lead to injury or
property damage if not avoided.
Indique un danger avec un niveau de risque faible des
blessures légères ou des dommages matériels si les
consignes de sécurité ne sont pas respectées.

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1.2 Further Safety Guidelines
Danger for ESD-sensitive components.
Les signes de danger pour les composants sensibles
aux décharges électrostatiques.
This symbol identifies important or additional
information regarding the operation of the safety
modules.

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1.3 General Requirements
Technical
Documentation
This technical documentation is a component of this product.
•This document must be accessible near the machine,
since it contains important instructions.
•The technical documentation should be included in the
sale, rental or transfer of the product.
Acceptance of Safety
Guidelines
Before handling the product to which this documentation
belongs, the operating instructions and safety guidelines mustbe
read. SIGMATEK GmbH & Co KG accepts no liability for
damages resulting from non-compliance with the Safety
guidelines or the applicable regulations.
Acceptance of the safety guidelines and the explanations in this
document, as well as the Safety System handbook are a basic
requirement for proper use. Therefore, read this operating
manual thoroughly and familiarize yourself with each of them in
detail.
More information on standards and regulations etc. can be found
in the system handbook
Qualified Personnel
Installation, assembly, programming and initial start-up,
operation, maintenance and decommissioning of control and
automation technology products in general, as well as Safety-
related products in particular, can only be performed by qualified
personnel.
Qualified personnel in this context are people who have
completed training or have trained under supervision of qualified
personnel and have been authorized to operate and maintain
safety-related equipment, systems and facilities in compliance
with the strict guidelines and standards of safety technology.

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Designated Use
The Safety modules are designed for use in safety-oriented
applications and meet the required conditions for safety
operation in compliance with Performancelevel e (PL e) CAT4 in
accordance with EN ISO 13849-1/-2 and SIL 3 in accordance
with EN 62061.
For your own safety and the safety of others, use Safety modules
for their designated purpose only. Correct EMC installation as
well as proper transport and storage are also included under
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 inconsistent with the
technical data described in this handbook.
Operator Due Diligence
The operator must ensure that
•the Safety modules are to be used for their designated
purpose only.
•the Safety modules are to be operated in error-free, fully
functional condition only.
•only sufficiently qualified and authorized personnel
operate the Safety modules.
•This documentation is complete and in readable
condition and available at the site of operation.

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2 Safety Conformity
2.1 Functional Safety Standards
- EN 62061
- EN ISO 13849-1
- EN ISO 13849-2
2.2 EU Conformity Declaration
EU Conformity Declaration
The SAI 041 conforms to the following European guidelines:
•2006/42/EG “Directive of the European Parliament and of the
Council of 17 May 2006 on Machinery and Change to the Directive
95/16/EC” (machine guideline)
•2014/30/EU “Electromagnetic Compatibility” (EMC guideline)
•2011/65/EU “Restricted use of certain hazardous substances in
electrical and electronic equipment” (RoHS Guideline)
The EU Conformity Declarations are provided on the SIGMATEK website.
Using the search function with the keyword “EU Declaration of Conformity”.

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2.3 Safety-Relevant Parameters
2.3.1 Horizontal Mounting position 0-60° C Environmental Temperature
Input Module
Two-channel application:
Safety parameters for two
connected sensors, which
are applicatively monitored in the used
controls (SCP 211, SCP 111-S)
Single-channel application
Safety parameters for one
connected sensor, which is monitored
in the SAI 041
SAI 041
In combination with
CPU module
SCP 211/SCP 111-S
PFHD = 2.3*10-8 (1/h)
MTTFd = 129 years
DC = 97 %
SFF = 99 %
PFHD= 1.7*10-8 (1/h)
MTTFd = 129 years
DC = 97 %
SFF = 99 %
PL e / CAT 4 according to EN/ISO 13849
SIL 3 according to EN 62061
PL e / CAT 3 according to EN/ISO 13849
SIL 3 according to EN 62061
The application for a specific PL,
category or SIL requires a risk analysis of
the end application, which for example,
determines whether two sensors are
sufficient.
These safety parameters were calculated
for the SAI 041 using sensor The Safety
parameters of the entire machine must
be determined in the end application.
One and two-channel application:
The application for a specific PL, category or SIL requires correct installation.
Please note possible normative requirements of the end application (machine)
for installation and selecting the sensor.
The use of the specified parameters requires a risk analysis of the end
application, by which must be determined, whether two sensors is sufficient.
For two-channel use, both sensors must be monitored in the Safety-oriented
application (SCP 211/111-S) for example, via the function block
SDINT_Compare.
2.4 Compatibility
For compatibility of the S-DIAS Safety modules, see chapter "Compatibility of
S-DIAS Safety Modules" in the system handbook.

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3 Technical Data
3.1 Analog Input Specifications
Number of channels
4
Measurement range
4-20 mA
Measurement value
12,000-60,000
Measurement range Overrange
and Under range1)
0.5-21.6 mA
Measurement range Overrange
and Under range
1500-64,800
Input type
differential input
Galvanic separation
none
Measurement range resolution
16 bits
ca. 0.371 µA/LSB
Conversion time for all channels
1 ms
Common mode range
±10 V
Load
typically 55 
Cable break monitor
configurable min. 0.5 mA
Input filter hardware
1 kHz, low pass 3rd order (common mode)
Input filter software
low pass 1st order (Configurable or can be deactivated)
Input delay
dependent on software filter3)
Measurement precision, 1-
channel
±1.0 %/200 µA2)
(0-60 °C)
Measurement precision, 2-
channel
±2.0%/400 µA2)
(0-60 °C)
Linearity
0.006 %
Status display
1x green status LED per channel, 1x red error LED per channel
1) A safety error is triggered if the value exceeds the upper or lower limits of this measuring range.
2) The measuring accuracy refers to the nominal measuring range of 4-20 mA
3) The input delay t in milliseconds can be calculated using the formula below
𝑡 = 5000
2 ∗ 𝜋 ∗ 𝑓𝑖𝑙𝑡𝑒𝑟 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦(𝐻𝑧)

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3.2 Measurement Range
The diagram shown below shows the configuration of the SAI 041’s measurement range. The
measurement range is configured to 4-20 mA by default. In the Safety Designer, the
measurement range can be expanded from 0.5-21.6 mA. Input currents< 0.5mA or > 21.6
mA trigger a safety error.
3.3 Electrical Requirements
Supply voltage sensor supply
typically +24 V DC ±20 % (SELV/PELV)
UL: Class 2 or LVLC
Protection class
III
Current consumption X51)
typically 3.5 mA internal consumption
maximum 5 mA internal consumption + connected sensors
(maximum 500 mA for sensor supply)
Current consumption
from the S-DIAS bus
+12 V
+24 V
with missing
+24 V connection (X5)
typically
100 mA
maximu
m 120
mA
typically
55 mA
maximum
65 mA
(1) The outgoing sensor supply for X1, X2, X3 and X4 are fed via X5. A common fuse is provided for the sensor
supplies with a maximum of 500 mA
USA and Canada:
The supply must be limited to:
a) max. 5 A at voltages from 0-20 V DC, or
b) 100 W at voltages from 20-60 V DC.
The limiting component (e.g., transformer, power supply or fuse) must be certified by an
NRTL (Nationally Recognized Testing Laboratory).
A supply voltage fuse with sufficient voltage and current limiting must be provided!
(Dependent on the number of modules connected on the S-DIAS Safety bus)
The S-DIAS Safety analog input module is supported by the SCP 211 (starting from FW
version v505) and the SCP 111-S (starting from FW version v465). The SCP 011 does not
support the S-DIAS Safety analog input module.
nominal measurement
range
Over range
Under range
Over range
Error
Under range
Error
0 mA
0.5 mA
21.6 mA
adjustable
adjustable

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The SAI 041 is currently not supported by the SCP 111.
When used in combination with an SAI 041, the Safety CPU must be supplied with at least
19.2 V!

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3.4 Miscellaneous
Article number
20-897-041
Hardware version
2.x
Approvals
CE, TÜV EG type tested
3.5 Environmental Conditions
Storage temperature
-40 ... +85°C
Environmental temperature
0 ... +60 °C1)
Humidity
0-95 %, non-condensing
Installation altitude above sea
level
0-2000 m without derating
>2000 m up to a maximum of 5000 m with derating of the maximum
environmental temperature by 0.5 °C per 100 m
Operating conditions
pollution degree 2
EMC resistance
EN 61000-6-7 (noise immunity requirements for devices
with functional safety)
EN 61000-6-2 (industrial area)
EMC noise generation
EN 61000-6-4 (industrial area)
Vibration resistance
EN 60068-2-6
3.5 mm from 5-8.4 Hz
1 g from 8.4-150 Hz
Shock resistance
EN 60068-2-27
15 g (147.15 m/s2)
Protection type
EN 60529
IP20
1) Starting at an ambient temperature of +55 °C, the safety parameter from chapter 2.3.1 must be used.

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4 Mechanical Dimensions

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5 Connector Layout
The connections of the +24 V supply (X5: pin 1 and pin 2) or the GND supply (X5: pin 3 and
pin 4) are internally bridged. To supply the module, only one connection to a +24 V pin (pin
1 or pin 2) and a GND pin (pin 3 or pin 4) is required. The bridged connections may be used
for further looping of the +24 V supply and the GND supply. However, it must be taken into
account that a total current of 6 A per connection is not exceeded by the forward looping!

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5.1 Status LEDs
Bus status
green
ON
bus communication OK
OFF
no supply available
BLINKING (5 Hz)
no communication
Safety Used
yellow
ON
module is used and no errors exist
OFF
module is not used or not in operational mode
Input Status
green
ON
analog input is active and input range valid
BLINKING (0.5 Hz)
analog input below measurement range
BLINKING (4 Hz)
analog input above measurement range
OFF
analog input inactive
Input error
red
OFF
no errors
BLINKS
safety error
DC OK
green
ON
+24 V input voltage for sensor supply OK
Sensor supply
yellow
ON
+24 V sensor supply active

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5.2 Applicable Connectors
Connectors:
X1-X5: Connectors with spring terminals (included with delivery)
The spring terminals are suitable for the connection of ultrasonically compressed
(ultrasonically welded) strands.
Connections:
Stripping length/sleeve length:
10 mm
Mating direction:
parallel to the conductor axis or circuit board
Conductor cross section rigid:
0.2-1.5 mm2
Conductor cross section flexible:
0.2-1.5 mm2
Conductor cross-section strands ultrasonically compacted:
0.2-1.5 mm2
Conductor cross section AWG/kcmil:
24-16
Conductor cross section flexible with ferrule without plastic
sleeve
0.25-1.5 mm2
Conductor cross section flexible with ferrule with plastic sleeve:
0.25-0.75 mm2(reason for reduction d2 of the
ferrule)
5.3 Label Field
Manufacturer
Weidmüller
Type
MF 10/5 CABUR MC NE WS
Article number Weidmüller
1854510000
Compatible printer
Weidmüller
Type
Printjet Advanced 230V
Article number Weidmüller
1324380000