Beckhoff EL2904 Operating Instructions Manual Download Page 1

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Operating instructions | EN

EL2904

TwinSAFE Terminal with 4 digital fail-safe outputs

2021-03-17 | Version: 2.3.0

Summary of Contents for EL2904

Page 1: ...Operating instructions EN EL2904 TwinSAFE Terminal with 4 digital fail safe outputs 2021 03 17 Version 2 3 0 ...

Page 2: ......

Page 3: ...terminal 14 2 2 5 The fail safe principle Fail Stop 14 3 Product description 15 3 1 EL2904 TwinSAFE terminal with 4 digital fail safe outputs 15 3 2 Intended use 16 3 3 Technical data 18 3 4 Safety parameters 19 3 5 Dimensions 20 3 6 Block diagram of the EL2904 21 4 Operation 22 4 1 Environmental conditions 22 4 2 Installation 22 4 2 1 Safety instructions 22 4 2 2 Transport storage 22 4 2 3 Electr...

Page 4: ...le addresses 37 4 4 5 Entering a TwinSAFE address and parameters in the System Manager 38 4 5 Diagnostics 40 4 5 1 Diagnostic LEDs 40 4 5 2 Diagnostic objects 41 4 5 3 Possible causes of diagnostic messages 43 4 6 Maintenance 44 4 7 Service life 44 4 8 Decommissioning 45 5 Appendix 46 5 1 Support and Service 46 5 2 Certificates 47 ...

Page 5: ... are valid Further information given on the product pages of the Beckhoff homepage in emails or in other publications is not authoritative Disclaimer The documentation has been prepared with care The products described are subject to cyclical revision For that reason the documentation is not in every case checked for consistency with performance data standards or other characteristics We reserve t...

Page 6: ...ion Modifications to hardware or software configurations other than those described in the documentation are not permitted and nullify the liability of Beckhoff Automation GmbH Co KG 1 2 2 Operator s obligation to exercise diligence The operator must ensure that the TwinSAFE products are only used as intended see chapter Product description the TwinSAFE products are only operated in sound conditio...

Page 7: ...dangers the life and health of persons WARNING Risk of injury Failure to follow this safety instruction endangers the life and health of persons CAUTION Personal injuries Failure to follow this safety instruction can lead to injuries to persons NOTE Damage to the environment equipment or data loss Failure to follow this instruction can lead to environmental damage equipment damage or data loss Tip...

Page 8: ...Foreword EL2904 8 Version 2 3 0 1 3 Documentation issue status ...

Page 9: ...ted Safety parameters updated Foreword revised 1 6 2 Block diagram updated Numbering table of contents changed Description of the reaction times added Reliability document updated 1 6 1 Certificate updated 1 6 0 Company address amended Safety parameters extended 1 5 0 Extended temperature range amended Notes regarding temperature measurement and EMC added Description of date code extended 1 4 1 Do...

Page 10: ...munication interface to the higher level controller and the terminals are the interface to sensors and actuators The whole bus station is clipped onto a 35 mm DIN mounting rail EN 60715 The mechanical cross connection of the bus station is established via a slot and key system at the Bus Coupler and the Bus Terminals The sensors and actuators are connected with the terminals via the screwless spri...

Page 11: ... mm Mounting on 35 mm mounting rail EN 60715 with locking Attachable by double slot and key connection Fig 2 Bus Coupler EtherCAT Connection technology Bus Coupler Wiring spring loaded system Connection cross section 0 08 mm 2 5 mm stranded wire solid wire Fieldbus connection depending on fieldbus Power contacts 3 spring contacts Current load 10 A Rated voltage 24 VDC ...

Page 12: ...e Fieldbus connection E bus Power contacts up to 3 blade spring contacts Current load 10 A Rated voltage depends on Bus Terminal type 2 1 3 E bus The E bus is the data path within a terminal strip The E bus is led through from the Bus Coupler through all the terminals via six contacts on the terminals side walls 2 1 4 Power contacts The operating voltage is passed on to following terminals via thr...

Page 13: ...mix of safe and standard signals Logical link of the I Os in the EL6900 TwinSAFE logic terminal Safety relevant networking of machines via bus systems TwinSAFE protocol FSoE Transfer of safety relevant data via any media genuine black channel TwinSAFE communication via fieldbus systems such as EtherCAT Lightbus PROFIBUS or Ethernet IEC 61508 2010 SIL 3 compliant Configuring instead of wiring the T...

Page 14: ... It enables the configuration of a simple flexible and cost effective decentralized safety control system Therefore there are no safety requirements for the higher level controller The typical safety functions required for the automation of machines such as emergency stop protective door two hand etc are already permanently programmed in the EL6900 The user configures the EL6900 terminal according...

Page 15: ...utputs for connecting actuators contactors relays etc with a maximum current 0 5 A 24 VDC The Bus Terminal has 4 fail safe outputs The EL2904 meets the requirements of IEC 61508 2010 SIL 3 EN ISO 13849 1 2015 Cat 4 PL e NRTL UL508 UL1998 and UL991 The TwinSAFE terminal has the typical design of an EtherCAT terminal Fig 4 EL2904 TwinSAFE terminal with 4 digital fail safe outputs ...

Page 16: ...ng TwinSAFE components have been developed for these tasks The EL1904 is an EtherCAT Terminal with 4 digital fail safe inputs The EL2904 is an EtherCAT Terminal with 4 digital fail safe outputs The EL6900 is an EtherCAT Terminal with integrated TwinSAFE logic These TwinSAFE components are suitable for operation on the Beckhoff EKxxxx series Bus Couplers Beckhoff CXxxxx series Embedded PCs with E b...

Page 17: ... of the TwinSAFE components according to EN 81 22 and EN 81 50 the conditions de scribed in the manuals for achieving category 4 according to EN ISO 13849 1 2015 must be observed The use of TwinSAFE components is limited to indoor applications Basic protection against direct contact must be provided either by fulfilling protection class IP2X or by installing the TwinSAFE components in a control ca...

Page 18: ...le ambient temperature operation from SW 04 CW 02 2014 25 C to 55 C see notes in section Example configuration for temperature measurement Permissible ambient temperature transport storage 40 C to 70 C Permissible air humidity 5 to 95 non condensing Permissible air pressure operation storage transport 750 hPa to 1100 hPa this corresponds to an altitude of approx 690 m to 2450 m above sea level ass...

Page 19: ...h the temperature limits The TwinSAFE component has a maximum internal temperature at which a switch off takes place This is designed for the maximum permissible ambient temperature If the derating factor for the temperature for higher altitudes is used the user is solely responsible for ensuring that the calculated maximum ambient temperature is complied with 3 4 Safety parameters Characteristic ...

Page 20: ...Product description EL2904 20 Version 2 3 0 3 5 Dimensions Fig 5 Dimensions of the EL2904 Width 24 mm side by side installation Height 100 mm Depth 68 mm ...

Page 21: ...diagram of the EL2904 The block diagram shows the basic configuration of a channel in the EL2904 The part with a red border is present four times in the terminal The high side and low side switches only exist once for all channels This means that each channel has a total of four stop paths ...

Page 22: ...h as mobile phones radio equipment transmitters or high frequency systems that exceed the interference emissions limits specified in the standards are operated near Twin SAFE components the function of the TwinSAFE components may be impaired 4 2 Installation 4 2 1 Safety instructions Before installing and commissioning the TwinSAFE components please read the safety instructions in the foreword of ...

Page 23: ...us Terminals or digital 4 channel Bus Termi nals do not or not fully loop through the power contacts Potential supply terminals EL91xx EL92xx interrupt the power contacts and thus represent the start of a new supply rail PE power contact The power contact labelled PE can be used as a protective earth For safety reasons this contact mates first when plugging together and can ground short circuit cu...

Page 24: ...ints are implemented in spring force technology Connect the cables as follows 1 Open a terminal point by pushing a screwdriver straight against the stop into the square opening above the terminal point Do not turn the screwdriver or move it alternately don t toggle 2 The wire can now be inserted into the round terminal opening without any force 3 The terminal closes automatically when the pressure...

Page 25: ... power contact 4 not used no function 5 not used no function 6 positive power contact 7 negative power contact 8 not used no function 1 1 Output 1 2 Output 1 3 3 Output 3 4 Output 3 5 2 Output 2 6 Output 2 7 4 Output 4 8 Output 4 Test pulses When selecting actuators please ensure that the EL2904 test pulses do not lead to actuator switch ing or diagnostic message from the EL2904 ...

Page 26: ...tted cable length When connecting a single actuator via its own continuous cabling or via a sheathed cable the maximum permitted cable length is 100 m The use of contact points connectors or additional actuators in the cabling reduces the maximum propagation Cable routing Fig 11 Cable routing ...

Page 27: ...able lengths and cause diagnostic messages If connection via a bus cable is unavoidable the test pulses can be switched off parameters Testing of outputs active and Current measurement active However this then leads to a reduction in the degree of diagnostic cover when calculating the performance level Test pulses The typical length of test pulse switching from 24 V to 0 V and back to 24 V is 300 ...

Page 28: ...lled horizontally and the mating surfaces of the EL KL terminals point toward the front see illustration below The terminals are ventilated from below which enables optimum cooling of the electronics through convection The direction indication down corresponds to the direction of positive acceleration due to gravity Fig 13 Installation position and minimum distances In order to ensure optimum conv...

Page 29: ...bles all 4 safe outputs during the measurement External heat sources radiant heat impaired convection The maximum permissible ambient temperature of 55 C was checked with the above example con figuration Impaired convection an unfavorable location near heat sources or an unfavorable config uration of the EtherCAT Terminals may result in overheating of the terminals The key parameter is always the ...

Page 30: ...ler Join the compo nents with slot and key and push the terminals against the mounting rail until the lock clicks onto the mounting rail If the terminals are clipped onto the mounting rail first and then pushed together without slot and key the connection will not be operational When correctly assembled no significant gap should be visible between the housings Fastening of mounting rails The locki...

Page 31: ...mbled terminal until they protrude loosely The lock with the mounting rail is now released for this terminal and the terminal can be pulled from the mounting rail without excessive force 2 Grasp the released terminal with thumb and index finger simultaneous at the upper and lower grooved housing surfaces and pull the terminal away from the mounting rail ...

Page 32: ...of the communication This is typically 3 times the EtherCAT cycle time since a new Safety over EtherCAT telegram has to be generated before new data can be sent These times depend directly on the higher level standard controller cycle time of the PLC NC RTLogic Response time of the logic terminal This is the cycle time of the logic terminal and typically ranges from 500 µs to 10 ms for the EL6900 ...

Page 33: ...s ms ms 4 2 6 Tested EL2904 devices The following list contains devices that were tested together with the EL2904 TwinSAFE terminal The results only apply for the current device hardware version at the time of testing The tests were carried out in a laboratory environment Modifications of these products cannot be considered here If you are unsure please test the hardware together with the TwinSAFE...

Page 34: ... rated operating voltage being exceeded by more than 40 due to short term interference voltages The individual terminals may only be unplugged or removed from the Bus Terminal system if the supply voltage has been switched off or if a non explosive atmosphere is ensured The connections of the certified components may only be connected or disconnected if the supply voltage has been switched off or ...

Page 35: ...system in areas potentially explosive atmosphere are available in the Download section of the Beckhoff website at http www beckhoff de 4 4 Configuration of the terminal in TwinCAT CAUTION Do not change CoE objects Do not change any of the CoE objects in the TwinSAFE terminals Any modifications e g via TwinCAT of the CoE objects will permanently set the terminals to the Fail Stop state or lead to u...

Page 36: ...Operation EL2904 36 Version 2 3 0 Fig 19 Inserting an EL2904 ...

Page 37: ...1 and 1023 are available DIP switch Address 1 2 3 4 5 6 7 8 9 10 ON OFF OFF OFF OFF OFF OFF OFF OFF OFF 1 OFF ON OFF OFF OFF OFF OFF OFF OFF OFF 2 ON ON OFF OFF OFF OFF OFF OFF OFF OFF 3 OFF OFF ON OFF OFF OFF OFF OFF OFF OFF 4 ON OFF ON OFF OFF OFF OFF OFF OFF OFF 5 OFF ON ON OFF OFF OFF OFF OFF OFF OFF 6 ON ON ON OFF OFF OFF OFF OFF OFF OFF 7 ON ON ON ON ON ON ON ON ON ON 1023 WARNING TwinSAFE a...

Page 38: ...nager The FSoE address set at the DIP switch must also be entered under the FSoE tab FSoE_Address entry Fig 21 Entering the FSoE address The EL2904 parameters are set under the respective TwinSAFE connection in the Connection and Parameter tabs Fig 22 Setting the connection of the TwinSAFE connection ...

Page 39: ...rminal errors can only be reset by switching the power supply off and back on again true false Store Code This parameter is required for the TwinSAFE Restore Mode 0x0000 Project CRC This parameter is required for the TwinSAFE Restore Mode 0x0000 Test pulses If the parameters Current Measurement active or Testing of outputs active are set to TRUE the ter minal generates test pulses at the outputs T...

Page 40: ... Error at output 3 rapid flickering alternating with 4 flash pulses Error at output 4 rapid flickering alternating with 5 flash pulses Field voltage too low rapid flickering alternating with 6 flash pulses Field voltage too high rapid flickering alternating with 7 flash pulses Internal terminal temperature too low rapid flickering alternating with 8 flash pulses Internal terminal temperature too h...

Page 41: ...al when you return it 4 5 2 Diagnostic objects CAUTION Do not change CoE objects Do not make any modifications to the CoE objects in the TwinSAFE components Any modifications e g using TwinCAT of the CoE objects will permanently set the TwinSAFE components to the Fail Stop state Index FA80hex Internal temperature values The CoE objects FA80hex indicate the current internal temperature values of th...

Page 42: ...inal temperature outside the specification RO 0 1bin Overtemperature µC1 0bin 1 1bin Overtemperature µC2 0bin 2 1bin Overtemperature of the output board 0bin 3 1bin Temperature too low µC1 0bin 4 1bin Temperature too low µC2 0bin 5 1bin Temperature of the output board too low 0bin 6 1bin Temperature difference on the processor board too large 0bin 7 1bin Temperature difference between the boards i...

Page 43: ...supply Switch on voltage at the power contacts before or at the same time as the terminal supply and reset the error dis play through PowerOn Reset of the terminal Voltage on the power contacts too low Increase the voltage at the power contacts and reset the error display through PowerOn Reset of the terminal EMC faults Take suitable EMC measures Internal defect Replace terminal Diag 2 LED Flash c...

Page 44: ... longer be operated WARNING Have soiled terminals checked Cleaning of the TwinSAFE component by the user is not permitted Please send soiled terminals to the manufacturer for inspection and cleaning 4 7 Service life The TwinSAFE terminals are designed for a service life of 20 years Due to the high diagnostic coverage within the lifecycle no special proof tests are required The TwinSAFE terminals b...

Page 45: ...accessories in Germany for proper disposal Transport costs will be borne by the sender Return the old devices with the note for disposal to Beckhoff Automation GmbH Co KG Service Department Stahlstrasse 31 D 33415 Verl Observe the applicable national laws and guidelines for disposal Housing components polycarbonate polyamide PA6 6 are suitable for plastic recycling Metal parts can be sent for meta...

Page 46: ...nents there Beckhoff Support Support offers you comprehensive technical assistance helping you not only with the application of individual Beckhoff products but also with other wide ranging services support design programming and commissioning of complex automation systems and extensive training program for Beckhoff system components Hotline 49 5246 963 157 Fax 49 5246 963 9157 e mail support beck...

Page 47: ...Appendix EL2904 47 Version 2 3 0 5 2 Certificates ...

Page 48: ...Appendix EL2904 48 Version 2 3 0 ...

Page 49: ... 26 Fig 11 Cable routing 26 Fig 12 Typical course of test pulses of the outputs 27 Fig 13 Installation position and minimum distances 28 Fig 14 Example configuration for temperature measurement 29 Fig 15 Installation on the mounting rail 30 Fig 16 Removal of mounting rails 31 Fig 17 Typical response time 32 Fig 18 Worst case response time 33 Fig 19 Inserting an EL2904 36 Fig 20 Address settings on...

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Page 51: ...Beckhoff Automation GmbH Co KG Hülshorstweg 20 33415 Verl Germany Phone 49 5246 9630 info beckhoff com www beckhoff com More Information www beckhoff com el2904 ...

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