Beckhoff TwinSAFE EL2912 Operating Instructions Manual Download Page 31 | Manualshive

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Operation

EL2912

31

Version: 1.0.0

NOTE

Route the signal cable separately

The signal cable must be routed separately from potential sources of interference, such as motor supply ca-
bles, 230 V

AC

power cables etc.!

Interference caused by cables routed in parallel can influence the signal form of the test pulses and thus
cause diagnostic messages (e.g. sensor errors or OpenLoad errors).
D: Distance between the cable ducts should be as large as possible
blue arrows: signal line
red arrows: potential source of interference

The common routing of signals together with other clocked signals in a common cable also reduces the
maximum propagation, since crosstalk of the signals can occur over long cable lengths and cause diagnostic
messages.

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Summary of Contents for TwinSAFE EL2912

Page 1: ...Operating Instructions for EL2912 TwinSAFE Terminal with 2 digital fail safe outputs 1 0 0 2019 09 06 Version Date ...

Page 2: ......

Page 3: ... Fail Stop 12 3 Product description 13 3 1 EL2912 TwinSAFE terminal with two fail safe outputs 13 3 2 Intended use 14 3 3 Technical data 16 3 4 Safety parameters 17 3 5 Safe output 18 3 6 Fuse 18 3 7 Dimensions 18 3 8 Using the integrated TwinSAFE Logic functions 19 3 9 Project design limits for the EL2912 19 4 Operation 21 4 1 Environmental conditions 21 4 2 Installation 21 4 2 1 Safety instructi...

Page 4: ...ic LEDs 39 4 5 3 Flash code display 40 4 5 4 Diagnostic objects 40 4 5 5 Cycle time of the safety project 42 4 5 6 Diagnosis History 43 4 5 7 Diag History tab 46 4 6 Maintenance 47 4 7 Service life 48 4 8 Decommissioning 48 4 9 Firmware update of TwinSAFE products 49 5 Appendix 52 5 1 Support and Service 52 5 2 Certificates 53 ...

Page 5: ...tation 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 res...

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: ...pointer This symbol indicates information that contributes to better understanding 1 3 Documentation issue status Version Comment 1 0 0 First release of the documentation 1 4 Version history of the TwinSAFE product This version history lists the software and hardware version numbers A description of the changes compared to the previous version is also given Updated hardware and software TwinSAFE p...

Page 8: ... EtherCAT Coupler and connected EtherCAT Terminals The EtherCAT Coupler forms the communication interface to the higher level controller while the EtherCAT Terminals form the interface to the sensors and actuators The whole bus station is clipped onto a 35 mm DIN mounting rail EN 60715 The mechanical link of the bus station is established with a slot and key system on EtherCAT Couplers and EtherCA...

Page 9: ...0 mm x 68 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 EtherCAT Power contacts 3 spring contacts Current load 10 A Nominal voltage 24 VDC ...

Page 10: ...d wire Communication E bus Power contacts Up to 3 blade spring contacts Current load 10 A Nominal voltage Depending on terminal type typically 24 VDC 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 t...

Page 11: ...ogic component Due to the enormous flexibility of the system several TwinSAFE logic components can also be operated simultaneously in a network 2 2 2 Safety concept TwinSAFE Safety and I O technology in one system Extension of the familiar Beckhoff I O system with TwinSAFE Terminals Freely selectable mix of safe and standard signals Logic link of the I Os in the TwinSAFE logic component e g EL6910...

Page 12: ... logic component Typically meet the requirements of IEC 61508 2010 up to SIL 3 and EN ISO 13849 1 2015 up to Category 4 PL e More detailed information can be found in the respective user documentation 2 2 3 The fail safe principle Fail Stop The basic rule for a safety system such as TwinSAFE is that failure of a part a system component or the overall system must never lead to a dangerous condition...

Page 13: ...g standards EN 61508 2010 SIL 3 EN 62061 2005 A2 2015 SIL CL 3 EN ISO 13849 1 2015 Cat 4 PL e The TwinSAFE terminal has the typical design of a 12 mm EtherCAT Terminal The outputs use the voltage of the power contacts In addition the voltage of the power contacts is applied to terminal points 2 6 and 3 7 The terminal points GND1 GND2 and GND UP terminal points 3 7 are directly connected internally...

Page 14: ...stic message of the TwinSAFE component The following TwinSAFE components were 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 EL6910 is an EtherCAT Terminal with integrated TwinSAFE logic These TwinSAFE components are suitable for operation on the Beckhoff EKxxxx series Bus Couplers...

Page 15: ...1 0 0 CAUTION Follow the machinery directive The TwinSAFE components may only be used in machines as defined in the machinery directive CAUTION Ensure traceability The buyer has to ensure the traceability of the device via the serial number ...

Page 16: ...le 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 assuming an international standard atmos phere Climate category according to EN 60721 3 3 3K3 the deviation from 3K3 is possible only with optimal environmen tal conditions and also applies only to the technical da...

Page 17: ...ximum 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 numbers EL2912 Lifetime a 20 Prooftest Interval a not re...

Page 18: ...cross circuit or external power supply must lead to the switch off of all of these modules This is achieved by setting the Module Fault Link active parameter for all modules involved This parameter is set to TRUE by default 3 6 Fuse Power supply of the power contacts The safe outputs are supplied from the power contacts The current carrying capacity of the power contacts is limited to 10 A The pow...

Page 19: ...afe TwinSAFE I O slave please delete the logic the mapping and the parameter data on the EtherCAT Terminal and switch the voltage off and on again Fig 6 Delete project data 3 9 Project design limits for the EL2912 Project design limits The maximum project design size of the EL2912 is limited by the available memory This is man aged dynamically The values specified in the following table are theref...

Page 20: ...ta per TwinSAFE connection maximum 126 bytes telegram length 255 bytes TwinSAFE function blocks maximum 512 For using ESTOP function blocks with complete input and output mapping Other function blocks may lead to a lower maximum number TwinSAFE groups maximum 128 TwinSAFE user maximum 40 Standard PLC inputs dynamic memory dependent max 1484 bytes Standard PLC outputs dynamic memory dependent max 1...

Page 21: ...ere devices such 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 t...

Page 22: ...st be terminated on the right side with the EL9011 or EL9012 end cap to ensure the protection class and ESD protection Fig 7 Spring contacts of Beckhoff I O components 4 2 3 2 Control cabinet terminal box The TwinSAFE terminals must be installed in a control cabinet or terminal box with IP54 protection class according to IEC 60529 as a minimum 4 2 3 3 Installation position and minimum distances Fo...

Page 23: ...vorable location near heat sources or an unfavorable configu ration of the EtherCAT Terminals may result in overheating of the TwinSAFE components The key parameter is always the maximum permitted internally measured temperature of 110 C above which the TwinSAFE components switch to safe state and report an error The internal temperature can be read from the TwinSAFE components via CoE 4 2 3 5 Not...

Page 24: ... rather unfavorable as terminals with relatively high waste heat are attached directly to the EtherCAT Coupler or the power supply terminal with high E bus load The additional external heating of the TwinSAFE terminals by the adjacent power supply units increases the internal terminal temperature which can lead to the maximum permissible temperature being exceeded This leads to the diagnosis Overt...

Page 25: ...Operation EL2912 25 Version 1 0 0 Fig 10 Thermally favorable arrangement of the TwinSAFE terminals ...

Page 26: ...Coupler 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 l...

Page 27: ...bus The six spring contacts of the E bus deal with the transfer of the data and the supply of the Bus Terminal electronics NOTE Observe the E bus current Observe the maximum current that your Bus Coupler can supply to the E bus Use the EL9410 Power Sup ply Terminal if the current consumption of your terminals exceeds the maximum current that your Bus Cou pler can feed to the E bus supply Power con...

Page 28: ...ogy 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 is released holding the wire safely and per...

Page 29: ...tion Terminal point Input Output Signal 1 Output1 Output 1 24 VDC 2 24VDC UP 3 GND UP 4 Output2 Output 2 24 VDC 5 GND1 Output 1 GND directly connected to GND UP 6 24VDC UP 7 GND UP 8 GND2 Output 2 GND directly connected to GND UP Power contact top 24VDC UP Power contact low GND UP ...

Page 30: ...2912 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 small cable cross sections in the wiring reduces the maximum expansion Cable routing Fig 16 Cable routing ...

Page 31: ...nfluence the signal form of the test pulses and thus cause diagnostic messages e g sensor errors or OpenLoad errors D Distance between the cable ducts should be as large as possible blue arrows signal line red arrows potential source of interference The common routing of signals together with other clocked signals in a common cable also reduces the maximum propagation since crosstalk of the signal...

Page 32: ...nently set the terminals to the Fail Stop state or lead to unexpected behavior of the terminals 4 3 1 Inserting a Bus Coupler See TwinCAT automation software documentation 4 3 2 Inserting a Bus Terminal See TwinCAT automation software documentation 4 3 3 Adding an EL2912 An EL2912 is added in exactly the same way as any other Beckhoff EtherCAT Terminal Open TwinSAFE Terminals item in the list and ...

Page 33: ...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 34: ...iguration The connection and device specific parameters are set via the alias devices Fig 19 Starting the automatic import from the I O configuration If the automatic import is started from the I O configuration a selection dialog opens in which the individual terminals to be imported can be selected Fig 20 Selection from the I O tree The alias devices are created in the safety project when the di...

Page 35: ...the user 4 3 6 EL2912 parameters in TwinCAT After creating the alias device it can be parameterized according to the user specifications The FSoE address is set under the Linking tab and the link to the physical device is created Fig 22 Linking tab of the alias device ...

Page 36: ...01 ModuloDiagTestPulse 0x00 integer Modulo value for the frequency of the generation of a test pulse 0 every time 1 every 2nd time 80x0 02 MultiplierDiagTestPulse 0x01 integer Length of the test pulse in multiples of 400 µs 80x0 03 Standard outputs active FALSE Boolean Activation of the logical AND operator of the safe and standard outputs of the module 80x0 04 Diag TestPulse active TRUE Boolean A...

Page 37: ...0 Safe output 1 FSOUT Module 1 ErrAck OUT 0 1 Error Acknowledge for safe output 1 FSOUT Module 2 Output OUT 0 2 Safe output 2 FSOUT Module 2 ErrAck OUT 0 3 Error Acknowledge for safe output 2 4 4 TwinSAFE reaction times The TwinSAFE terminals form a modular safety system that exchanges safety oriented data via the Safety over EtherCAT protocol This chapter is intended to help you determine the sys...

Page 38: ...f the actuator This information is typically provided by the actuator manufacturer WDComm Watchdog time of the communication The typical response time is based on the following formula 3 3 typ Sensor Input Comm Logic Comm Output Actuator ReactionTime RT RT RT RT RT RT RT with 5 4 3 1 10 3 1 3 20 48 typ ReactionTime ms ms ms ms ms ms ms ms Worst case response time The worst case response time is th...

Page 39: ...ashes an environment error code applies Diag 2 red Together with Diag 3 and 4 Global shutdown1 has occurred see diag history of the TwinSAFE components Logic or environment error code according to Diag1 and tables below is output Together with Diag 3 and 4 Global fault1 has occurred see diag history of the TwinSAFE components Diag 3 red Global fault or global shutdown on µC11 No global fault or gl...

Page 40: ...ded 2 Supply voltage µC1 below minimum value 3 Maximum supply voltage µC2 exceeded 4 Supply voltage µC2 below minimum value 5 Maximum internal temperature exceeded 6 Internal temperature below minimum value 7 Valid temperature difference between µC1 and µC2 exceeded 8 reserved 9 reserved 10 General error 4 5 3 Flash code display LED Display Description flashing 400 ms ON 400 ms OFF 1 second pause ...

Page 41: ...C2 CRC of the firmware on µC2 RO F985 04 Vendor data CRC C2 CRC of the vendor data on µC2 RO Diagnostics history Any errors which occur during operation of the TwinSAFE component such as overtemperature or undervoltage are entered in the diagnostics history with a corresponding timestamp Index F100hex FSLOGIC status The CoE object F100hex shows the current status of the TwinSAFE component Index Na...

Page 42: ...FE connections are processed 8 PREPARE The PREPARE state is assumed at the transition from START to RUN or from SAFE to RUN In the PREPARE state the stored data read in from the FRAM is checked and then the RUN state is assumed If an error is detected during checking of the stored data all TwinSAFE groups assume the initial state STOPERROR If no error is detected during checking of the stored data...

Page 43: ...6 Min Safety Control Task Execution Time Minimum execution time of the TwinSAFE logic with a logic state of 1 Cycle time 1 25 value RO 0 hex FEA0 17 Max Safety Control Task Execution Time Maximum execution time of the TwinSAFE logic with a logic state of 1 Cycle time 1 25 value RO 0 hex Resetting the values The max and min values can be reset by writing a value to the CoE object 0x1C32 08 4 5 6 Di...

Page 44: ... 0 10F3 45 Diagnosis Message 064 Diagnosis message 64 BYTE 32 RO 0 Structure of the diagnosis messages DiagCode 4 bytes in this case always 0x 0000 E000 Flags 2 bytes diagnosis type info warning or error time stamp and number of parameters contained see the following table Text ID 2 bytes ID of the diagnosis message as a reference to the message text from the ESI XML Time stamp 8 bytes local slave...

Page 45: ...E device On the basis of the Text ID contained in the diagnostic message the corresponding plain text message can be found in the respective languages The parameters can be inserted in the appropriate positions In the following example x is used for a hexadecimal representation of the parameters Fig 30 ESI XML message text Via the entry New Messages Available the user receives information that new...

Page 46: ...ree structure and then selecting the Diag History tab Use the Update History button to fetch the current data from the TwinSAFE component Errors within the logic the function blocks the connections or the component itself are stored with a corresponding time stamp Fig 32 Diag history Use the Advanced button to open the advanced settings Here the user can customize the behavior of the diag history ...

Page 47: ...ance Maintenance The TwinSAFE components are maintenance free Environmental conditions WARNING Observe the specified environmental conditions Please ensure that the TwinSAFE components are only stored and operated under the specified conditions see technical data If the TwinSAFE component is operated outside the permitted temperature range it will switch to Global Shutdown state Cleaning Protect t...

Page 48: ... Decommissioning WARNING Risk of electric shock Bring the bus system into a safe de energized state before starting disassembly of the devices Disposal In order to dispose of the device it must be removed In accordance with the WEEE Directive 2012 19 EU Beckhoff takes back old devices and accessories in Germany for proper disposal Transport costs will be borne by the sender Return the old devices ...

Page 49: ...tor the machine state It is necessary that you have control over the machine i e you can see it and thus ensure that it is in a safe state and that a firmware update can be carried out without endangering the operators or other personnel NOTE Avoid communication interruptions during the download Please avoid disconnecting the EtherCAT connection while downloading the firmware under any circum stan...

Page 50: ... No Nein 4 The system is now in Configuration mode Fig 35 Firmware update of TwinSAFE products Part 1 To perform the firmware update select the Online tab 6 for the EtherCAT Device 5 If you want to update several components you can select the corresponding components 7 together for individual components select only these Subsequently click with the right mouse button inside the selected area and s...

Page 51: ... select the firmware file 9 and click Open 10 Confirm the window that then opens with OK 11 the firmware update is then performed After successful completion you must click OK 12 in the concluding Function Succeeded window You can then switch the system back to Run mode and use the TwinSAFE system Fig 37 Firmware update of TwinSAFE products Part 3 ...

Page 52: ...eckhoff components there Beckhoff Headquarters Beckhoff Automation GmbH Co KG Huelshorstweg 20 33415 Verl Germany Phone 49 5246 963 0 Fax 49 5246 963 198 e mail info beckhoff com 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 com...

Page 53: ...Appendix EL2912 53 Version 1 0 0 5 2 Certificates ...

Page 54: ...Cable routing 30 Fig 17 Adding an EL2912 32 Fig 18 Address settings on TwinSAFE terminals with 1023 possible addresses 33 Fig 19 Starting the automatic import from the I O configuration 34 Fig 20 Selection from the I O tree 34 Fig 21 Creating alias devices by the user 35 Fig 22 Linking tab of the alias device 35 Fig 23 Connection tab of the alias device 36 Fig 24 EL2912 parameters 36 Fig 25 EL2912...

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