Selection of Hirschmann cSCALE S6/C8 Mobile Safety Controller

Each power base module is integrated with 2 series connected safety cut-off relays (1+1 redundancy) for emergency shutdown or safety status switching. These two relays can independently or simultaneously disconnect the load circuit under safety logic control, ensuring reliable disconnection in case of dangerous movement or overload.

Chapter 3 Modular I/O Configuration and Selection

3.1 Power Base Module (with I/O)

The cSCALE system starts from the power base module and is equipped with a built-in DC/DC power supply (compliant with ISO 7637-2 car power standard) and basic I/O. Three types of power supply:

Type A: Internal power supply, only providing power.

Type B: External 8.2V NAMUR input (for proximity sensors, etc.), integrated NAMUR interface.

Type C: Powered by 12V CAN bus, suitable for in car networks.

The base module also provides diagnostic LEDs (power ON, power OK, safety relay ON, RUN, Error, and user programmable LEDs).

3.2 Selection of IP20 and IP66/67 I/O modules

According to the installation location (inside the control cabinet or directly outdoors), users can choose IP20 or IP66/67 versions of I/O modules. The mainstream I/O types include:

DI (Digital Input): With HSC (High Speed Counting) option, the highest counting frequency can process encoder signals.

DI DIAG: Digital input with extended diagnostics, capable of detecting short circuits and broken wires.

DI NAMUR: A digital input specifically designed for NAMUR proximity sensors.

AI 4... 20mA: Analog input (4~20mA), some channels can be switched to 0~10V.

AI 0-UB: Wide range analog input (up to 36V), can be used as 0~10V or digital input.

DO (Digital Output): 1A average current, high side drive.

DO PWM with CC: PWM output with current control, 2A or 4A version, adjustable frequency from 50 to 400Hz, used for directly driving hydraulic proportional valves.

8.2V/500mA power output: for external sensors (such as NAMUR).

12V/500mA CAN power supply: for CAN bus devices.

Configuration example (manual legend):

Basic type (28 I/O): 4 DI+HSC, 8 DI DIAG, 8 AI, 4 DO, 4 DO PWM, 1 safety relay.

Expansion type (100 I/O): 8 DI+HSC, 20 DI DIAG, 24 AI, 32 DO, 14 DO PWM, 2 DO PWM 4A, 1 safety relay.

High density type (168 I/O): 24 DI+HSC, 40 DI DIAG, 16 AI, 60 DO, 24 DO PWM, 4 DO PWM 4A, 1 safety relay.

3.3 Local I/O Expansion

Through the SYS ext interface, IP20 and IP66/67 controllers can be connected to expansion racks (up to 6 I/O modules), enabling up to 208 additional I/O points. The expansion module communicates with the main CPU through a dedicated high-speed bus to ensure real-time performance.

Chapter 4 Communication Interface and Network Integration

4.1 Built in communication capability

Ethernet: 10/100 Base-T (M12 connector), supports TCP/IP, can be used for programming, HMI communication, and remote monitoring.

USB 2.0: Used for firmware updates, data recording (via USB flash drive), and program downloads.

CAN: Supports CANopen, CANopen Safety, J1939 (SAE J1939 commercial vehicle protocol), and can be expanded to up to 6 independent CAN interfaces (through expansion modules).

4.2 CANopen Safety and J1939

CANopen Safety: Complies with EN 50325-5 and enables the exchange of safety related data (such as emergency stop signals and safety limits).

J1939: Native support, suitable for scenarios such as trucks and agricultural machinery that require communication with the engine ECU.

4.3 Distributed Control Architecture

CSCALE supports centralized or distributed control architectures. Multiple cSCALE controllers or third-party devices can be networked through CANopen or Ethernet to achieve collaborative control of large mobile devices. The redundant system architecture (primary/backup) further improves the availability of critical applications.

Chapter 5 Programming Environment and Development Support

5.1 CoDeSys and IEC 61131-3

All cSCALE controllers support CoDeSys (version 2.3 or 3.5, depending on the model) and comply with IEC 61131-3 standards (IL, ST, FBD, LD, SFC). Users can use familiar languages to write logic, security functions, and HMI interactions. Pre certified functional blocks, such as safety cutoff and emergency stop monitoring, can accelerate development.

5.2 C/C++Programming

For scenarios that require high-performance algorithms or complex data processing, cSCALE supports C/C++native programming, allowing engineers to directly access hardware resources and implement more efficient custom algorithms.

5.3 Unified software platform

The entire series of controllers use the same software platform, and applications can be migrated between different CPUs (taking into account I/O mapping differences), reducing training costs and maintenance complexity. Firmware updates can be easily completed through a USB memory stick.

5.4 Security Development Support

WIKA Mobile Control provides the following authentication support services:

Design and verification of security functions/security chains

SISTEMA calculation (performance level evaluation based on EN ISO 13849-1)

Application Programming (C/C++/IEC 61131)

Technical support during the TUV certification process

Chapter 6 Typical Applications and Selection Suggestions