SIGMA TEK CSTO 082 User manual

C-DIAS SAFETY DIGITAL OUTPUT MODULE CSTO 082
1.5 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
17.02.2016
11
Switching-off inductive loads
1.2
15.05.2017
12
Specifications of maximum allowable output loads re-
fined
1.3
04.12.2017
5, 8, 9, 14
8
14
15
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 7.05 auf 7.05E-09 geändert
Changed EMC resistance to 61000-6-2:2005
1.4
31.01.2018
9
Note Safety outputs protected polarity changed
1.5

CSTO 082 C-DIAS SAFETY-DIGITAL OUTPUT MODULE
Page 2 31.01.2018
Contents
List of Illustrations............................................................................................... 3
List of Tables........................................................................................................ 3
Explanation of Safety Symbols........................................................................... 4
Documentation Note............................................................................................ 4
Delivery Condition ............................................................................................... 4
Operator Due Diligence....................................................................................... 4
Installation............................................................................................................ 5
General Instructions for Operating the Safety Modules .................................. 5
The C-DIAS bus and Connector Layout........................................................................6
Designated Use.................................................................................................... 9
Mechanical Dimensions .................................................................................... 10
Technical Data.................................................................................................... 11
Output specifications...................................................................................................11
Maximum inductive load L (mH) at load current I (A)..................................................12
Maximum capacitive load C (µF) at load current I (A).................................................12
Electrical requirements................................................................................................13
Safety Conformity.............................................................................................. 14
Conformity with EU Standards ....................................................................................14
Functional safety standards ........................................................................................14
Safety parameters.......................................................................................................14
Environmental conditions............................................................................................15
Miscellaneous .............................................................................................................15
Output Power Supply ........................................................................................ 15
CSTO 082 Circuit................................................................................................ 16
LED Display........................................................................................................ 17
Connector Layout .............................................................................................. 18

C-DIAS SAFETY DIGITAL OUTPUT MODULE CSTO 082
1.5 Page 3
Connector Plug Coding.....................................................................................19
Error Response ..................................................................................................20
Restart Errors ............................................................................................................. 20
Troubleshooting.......................................................................................................... 21
Troubleshooting with the SafetyDesigner................................................................... 21
Correcting a wiring error............................................................................................. 21
Output Circuit.....................................................................................................22
Practical Example of a Circuit...........................................................................23
Requirements............................................................................................................. 23
Implementation........................................................................................................... 24
Connection Diagram................................................................................................... 25
List of Illustrations
Fig. 1: Example of a minimum system for a safety-related control.........................................6
Fig. 2: CSTO 082....................................................................................................................8
Fig. 3: Mechanical dimensions.............................................................................................10
Fig. 4: Inductive load ............................................................................................................12
Fig. 5: Capacitive load..........................................................................................................12
Fig. 6: CSTO 082 circuit .......................................................................................................16
Fig. 7: Connector plug coding...............................................................................................19
Fig. 8: Simplified status diagram ..........................................................................................20
Fig. 9: Output circuit structure ..............................................................................................22
Fig. 10: Simplified representation of the processing machine..............................................23
Fig. 11: Example structure diagram......................................................................................24
List of Tables
Table 1: C-DIAS bus connector layout ...................................................................................6
Table 2: Input specifications.................................................................................................11
Table 3: Allowable output loads............................................................................................12
Table 4: Electrical requirements...........................................................................................13
Table 5: Safety parameters ..................................................................................................14
Table 6: Environmental conditions .......................................................................................15
Table 7: Miscellaneous.........................................................................................................15
Table 8: LED Display............................................................................................................17
Table 9: Connector layout ....................................................................................................18
Table 10: Connection diagram example...............................................................................25

CSTO 082 C-DIAS SAFETY-DIGITAL OUTPUT MODULE
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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
explicitly.
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 OUTPUT MODULE CSTO 082
1.5 Page 5
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
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. Important is that the connector 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.

CSTO 082 C-DIAS SAFETY-DIGITAL OUTPUT MODULE
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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 OUTPUT MODULE CSTO 082
1.5 Page 7
The minimum system of a safety-related control with the CSTO 082, as shown above, is
formed with a C-IPC a CMB 081 and a Safety CPU or type CSCP 012 for example.
The safety-related application is found in the Safety CPU after configuration 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 be-
tween 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 can be found
in the Safety CPU handbook under the chapter "Handling the micro SD card". With regard
to the configuration using the design tool, the SafetyDesign handbook must be consulted.

CSTO 082 C-DIAS SAFETY-DIGITAL OUTPUT MODULE
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C-DIAS Safety Digital Output Module CSTO 082
Module Description
The Safety output component series has the Safety integrity
level SIL3 and/or SIL CL 3 according to (IEC 62061) and/or
Performance level e / Category 4 (EN ISO 13849)
The Safety output component series has:
8 safe outputs (IEC/EN 61131)
The safe outputs are used for the Safety-related output of
8 actuator signals to, for example, control relays, valves,
etc.
Fig. 2: CSTO 082
The Safety output module CSTO 082 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 output 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.
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.

C-DIAS SAFETY DIGITAL OUTPUT MODULE CSTO 082
1.5 Page 9
Designated Use
The CSTO 082 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, 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
CSCP 012, 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.

CSTO 082 C-DIAS SAFETY-DIGITAL OUTPUT MODULE
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Mechanical Dimensions
Fig. 3: Mechanical dimensions

C-DIAS SAFETY DIGITAL OUTPUT MODULE CSTO 082
1.5 Page 11
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 …
8
Rated output voltage
+24 V DC
Output voltage range
minimum +18 V
maximum +30 V
Maximum output current per
channel
2 A
Maximum total current per
output group (2 outputs)
2 A
Maximum total current
(complete module)
8 A
up to a max. 45 °C
ext. temperature
6 A
up to a max. 50 °C
ext. temperature
4 A
up to a max. 55 °C
ext. temperature
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
maximum 1.2 Joule (entire module)
Turn-on delay
< 200 µs
Turn-off delay
< 1 ms
Miscellaneous
short-circuit proof
Cut-off test signal
< 1.5 ms
Table 2: Input specifications

CSTO 082 C-DIAS SAFETY-DIGITAL OUTPUT MODULE
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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

C-DIAS SAFETY DIGITAL OUTPUT MODULE CSTO 082
1.5 Page 13
Electrical requirements
The Safety modules' electrical supply must also be provided over the C-DIAS bus in a
stand-alone system; another type and method of energy supply is not allowed.
The C-DIAS bus system's external 24 V supply voltage be generated by a PELV power
supply.
Rated supply voltage
+24 V DC (C-DIAS bus)
Supply voltage range
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
Output
(General use Ampere Rating)
18 - 30 V DC
2 A per channel,
2 A per group,
maximum 4 A complete module

CSTO 082 C-DIAS SAFETY-DIGITAL OUTPUT MODULE
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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
- EN/IEC 62061 SIL 3 or SIL CL 3
- EN ISO 13849 PL e / Cat. 4
Configuration: 2-channel redundant (diverse)
Safety parameters
Diagnostic coverage
DC [%]
95.94
Probability of failure per hour
PFHD[1/h]
7.05E-09
Mean time to dangerous failure
MTTFd [years] symmetrized
351
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.

C-DIAS SAFETY DIGITAL OUTPUT MODULE CSTO 082
1.5 Page 15
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 62061
Shock resistance
EN 60068-2-27
15 g
Protection Type
EN 60529
IP 20
Table 6: Environmental conditions
Miscellaneous
Article number
12-892-082
Hardware version
1.x
Table 7: Miscellaneous
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.

CSTO 082 C-DIAS SAFETY-DIGITAL OUTPUT MODULE
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CSTO 082 Circuit
Fig. 6: CSTO 082 circuit
For the functions and LED display, see the following chapter "LED
Displays".

C-DIAS SAFETY DIGITAL OUTPUT MODULE CSTO 082
1.5 Page 17
LED Display
The LED display lights continuously to indicate that the in- and outputs are active.
Label
Color
Function
Display
1 - 8
Yellow
Digital outputs 1 –8
(connector X1, X2)
Fast blinking frequency (wiring error, cross circuit... )
DC
Green
DCOK +24 V
Indicates that the +24 V supply for outputs and clock
signals are 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
currently in Idle or Check Configuration
mode
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

CSTO 082 C-DIAS SAFETY-DIGITAL OUTPUT MODULE
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Connector Layout
Module connection
Label
Pin
Function
Connector
X1: digital outputs (Group G1/G2)
X2: digital outputs (Group G3/G4)
X3: Power supply
Table 9: 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 (group 1)
X1 / 1
Digital output 1
TO2 (group 1)
X1 / 2
Digital output 2
TO3 (group 2)
X1 / 3
Digital output 3
TO4 (group 2)
X1 / 4
Digital output 4
TO5 (group 3)
X2 / 1
Digital output 5
TO6 (group 3)
X2 / 2
Digital output 6
TO7 (group 4)
X2 / 3
Digital output 7
TO8 (group 4)
X2 / 4
Digital output 8
+
X3 / 1
+24 V (output supply)
+
X3 / 2
+24 V (output supply)
-
X3 / 3
GND
-
X3 / 4
GND

C-DIAS SAFETY DIGITAL OUTPUT MODULE CSTO 082
1.5 Page 19
Connector Plug Coding
Fig. 7: Connector plug coding
The Phoenix connector sets used are coded at the factory to avoid confusing the connec-
tions. A red coding pin is thereby placed in the socket. Concurrently, the protruding "nose"
is removed from the corresponding pin in the plug. The respective plug can therefore only
be inserted into the corresponding socket.
Connector plug coding: Pin 1 in plug/socket X1
Pin 2 in plug/socket X2
The X3 plug is not coded.
Plug X2
Plug X1
Socket X2
Coding pin 2 (Pin 2)
Socket X1
Coding
pin 1
(Pin 1)

CSTO 082 C-DIAS SAFETY-DIGITAL OUTPUT MODULE
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Error Response
In the event of an error, please consult the chapter "LED Displays", as important infor-
mation on the runtime status of the system can be derived from the status and error dis-
play. Since errors in general are of a complex nature, do not perform a diagnosis based on
the LEDs alone (consult the corresponding chapter in the Safety System Handbook as
well). For an exact error analysis, the SafetyDesigner must be used.
Restart Errors
The following diagram shows the response of the Safety output module during restart.
Idle
Check Config.
Mode
Op. Mode
Error
Mode
RN
dauerhaft ON
Wiederanlauf
E
ST
blinken
dauerhaft ON
POST Service
Mode
Flash
Safe-CPU
ist leer
dauerhaft ON
Fig. 8: Simplified status diagram
Flash
Safe-Cpu
is Empty
Restart
Continously on
Continously on
Continously on
Blink