1TwinSAFE

New Automation Technology

2TwinSAFE

Beckhoff TwinSAFE: safety and standard I/O in one system

3TwinSAFE

TwinSAFE-Features

totally integrated in the Beckhoff busterminal system

easy to use out of the Beckhoff TwinCAT System

same modularity like the standard bus terminals

supported for PROFIBUS, RT Ethernet, EtherCAT etc.

certified IEC61508, EN954, ISO13849, etc.

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Advantages of TwinSAFE

reduces the wiring expenditure

shortens project engineering and start-up

reduces the expenditure of a plant extension or concatenation

increases the flexibility

small space requirement: 12 mm or 24 mm width

TwinSAFE communication protocol is open for all bus systems

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Safety engineering in modern automation

mixed network for standard and safety functions standard network with a decentralized safety island separate networks for standard and safety functions

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Plant concatenation with TwinSAFE

Machine „A“ Machine „B“ Machine „C“

TwinSAFE data TwinSAFE data

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TwinSAFE system configuration KL1904: Safety terminal, 24 V DC

4 safety inputs and 4 clock outputs

developed and certified in accordance with

IEC/EN 61508 up to SIL 3

EN 954 up to Cat. 4

ISO/EN 13849–1 up to PL e

high diagnosis

Communication error

Processor error

Sensor error(external supply, transverse conclusion etc..)

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TwinSAFE system configuration KL2904: Safety Output terminal 0,5 A 24 V DC

-K1-K2

-K3-K4

4 safety outputs

developed and certified in accordance with

IEC/EN 61508 up to SIL 3

EN 954 up to Cat. 4

ISO/EN 13849–1 up to PL e

high diagnosis

Communication error

Processor error

Actuator error

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TwinSAFE system configuration KL6904: Safety Logic-Terminal 0,5 A 24 V DC

-K1-K2

-K3-K4

4 safety outputs

developed and certified in accordance with

IEC/EN 61508 up to SIL 3

EN 954 up to Cat. 4

ISO/EN 13849–1 up to PL e

high diagnosis

Communication error

Processor error

Actuator error

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- K1

KL6904 diagnostic functions of the safe output terminal

Actuator diagnosis

Short-circuit

Wire break

wrongly external supply wires

Terminal diagnosis

Undervoltage

Overvoltage

Temperature monitoring

internal equipment diagnosis

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KL1904 diagnostic functions of the safe output terminal

Sensor diagnosis

Short-circuit

Wire break

wrongly external supply wires

Terminal diagnosis

Undervoltage

Overvoltage

Temperature monitoring

internal equipment diagnosis

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S-address of KLx904

- S-address has to be set for each terminal

- The S-address has to be unique inside a system manager configuration

- S-address is binary coded (range from 1 to 1023 possible)

- in this example address 242 is set

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Communication between TwinSAFE terminals

KL6904

KL1904

TwinSAFE message from KL6904 to KL1904 (Master-Message)

TwinSAFE message from KL1904 to KL6904 (Slave-Message)

fieldbus

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FAQ

How many inputs and outputs can be used together with one KL6904?The logic terminal can be configured that you can use up to 31 connections. It will be shipped per default with 7 connections. A change of the terminal that it can handle up to 15 connections can be done from within a PLC program. One connection is 4 Inputs (KL1904) or 4 Outputs (KL2904).

Which TwinCAT version is needed to be able to run TwinSAFE?TwinCAT 2.10 Build 1307 + installation of the TwinSAFE verifier (both installations available on Beckhoff CD 12/2006).

Can TwinSAFE be used on non-TwinCAT PLCs?This is possible in principle, but it is not release at the moment. The customer has to program the transfer of the TwinSAFE telegrams inside his PLC and must use a TwinCAT system to do the download of the TwinSAFE configuration. It is planned to have the possibility to create a mapping list out of the system manager.

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FAQ

Things to keep in mind:

- BC and BX can not be used together with TwinSAFE terminals- DeviceNet, CANopen, INTERBUS, Sercos, Modbus, Seriell are not

supported. DeviceNet and CANopen is planned to be supported in the future.

- The download of the TwinSAFE configuration by using the serial interface of the coupler ist currently not possible.

- Light curtains and laser scanner can only be connected by using contactors. The direct connection to the input terminals is in preparation.

- proximity switches can be used together with our input terminals, but it has to be assured that they are not powered during the TwinSAFE startup process.

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Available bus couplers and firmware versions

Currently available (01/2007):

BK3120 Firmware BD00 (Release)

BK3150 Firmware B500 (Release)

BK2020 Firmware B2E2

BK1120 Firmware B700 (Release)

BK9000 Firmware BA00 (Release)

BK9100 Firmware B100 (Release)

CX9000 Image 2.14 (Release)

CX1000 with CX1100 Firmware B600 (Release)

CX1020 with CX1100 Firmware B600 (Release)

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Practice

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Step-by-Step description of the

TwinSAFE parametrisation

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Step 1: TwinSAFE terminals will be configured in the System Manager

TwinSAFE busterminal

standard busterminal

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Step 2a: Settings of the KL1904

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Step 2b: Settings of the KL2904

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Step 2c: Settings of the KL6904

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Step 3: Append a TwinSAFE Group

- A group consists of TwinSAFE terminals which are logically connected to one KL6904

- Communication errors inside this group results in the switching off of only this group. Other groups are not influenced.

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Step 4: Adding a function block

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Step 5: Direct allocation of the inputs and outputs with the System Manager

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Safety applications realized by certified function blocks

Restart

EDM for feedback circuits

Delayed Output

Output

E-Stop Inputs

Configure input settings

Example: Emergency Stop

Further FB‘s: Guard door monitoring, operating mode selection, AND, OR, etc..

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Configure input settings

Break contact

Signal value 1 – Output 1 (run)

Signal value 0 – Output 0 (safe)

Make contact

Signal value 0 – Output 1 (run)

Signal value 1 – Output 0 (safe)

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Connections

Connections will be created automatically when an input or output is used in a function block configuration inside that group

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Step 6: Load a TwinSAFE project

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Step 7: Verify and start the project

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Diagnosis KL6904

Diagnosis:

-Internal temperatures

-Error codes of µC1

-Error codes of µC2

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Diagnosis TwinSAFE group

Diagnosis online:-Group state-Run/Stop of group-ErrAck Signal-Error at one of the FBs-Communication error-Output error

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Diagnosis function block list

Diagnosis:-FB number-FB type-FB state-Diagnosis bits

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Diagnosis bits for function blocks

Diagnosis-Bits of Emergency-Stop:

Index 0-3: Discrepancy error (index 0 means inputgroup 1, index 3 means inputgroup4)

Index 4-5: EDM error (index 4 means EDM1, index 5 means EDM2)

Diagnosis-Bits of Machine Monitor:

Index 0-1: Discrepancy error MonIn (index 0 means inputgroup 1, index 1 means inputgroup 2)

Index 2: Discrepancy error Secure inputs

Index 4-5: EDM error (index 4 means EDM1, index 5 means EDM2)

Diagnosis-Bits Operation Mode:

Index 0: Discrepancy error

All other FBs (AND, OR, DECOUPLE) have no additional diagnosis flags

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Diagnosis for TwinSAFE connections

Diagnosis:-Connection number-Connection type

- Master- Slave

-State -Diagnosis flags

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Diagnosis bits for TwinSAFE connection

Diagnosis bits of connection:

Bit 0: (unexpected) Null-message received (e.g. when the K-Bus or fieldbus was interrupted)

Bit 1: invalid K-Bus stateBit 2: watchdog expiredBit 3: CRC2-errorBit 4: SeqNo-errorBit 5: Slave-error (error bits (Comm_Fault, WD_Fault) in the F_Status are

set)Bit 6: F- and I-Parameter are transmittedBit 7: ActivateFV-Bit in F_Control is set

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Configuration of a connection between two KL6904 by using

network variables

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Network variables

Create network variables as unicast

Add a variable as Master_Message or Slave_Message

For one connection you need one publisher and one subscriber on each side.

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Append TwinSAFE structure

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Settings of TwinSAFE structure

S-address of the communication partner must match

Watchdog time must be identical on both sides of the connection

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Attach TwinSAFE structure

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Mapping of the TwinSAFE signals into the PLC

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Mapping of TwinSAFE signals into the PLC

TwinSAFE in- and outputs:

Will be linked inside the TwinSAFE project to a PLC input variable

In the future there will be a diagnosis FB which maps all inputs and outputs directly to the PLC program.

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User administration and version history

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User administration and version history

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User administration and version history

Create user…

Save TwinSAFE project…

Stored in the history…

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export / importof the

TwinSAFE project

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Export

Choose export…

Save in xml file…

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Import

Choose import…

Restoring of the connections…

Restoring of links…

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Examples

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networked application

Publisher MASTER_MESSAGE Subscriber MASTER_MESSAGE

Publisher SLAVE_MESSAGESubscriber SLAVE_MESSAGE

Pub ID 10 Sub ID 10

MasterSlave

AmsNetID 5.0.227.207.1.1

MasterSlave

AmsNetID 5.0.227.208.1.1

MasterSlave

AmsNetID 5.0.227.209.1.1

Pub ID 11Sub ID 11

Publisher MASTER_MESSAGE Subscriber MASTER_MESSAGE

Publisher SLAVE_MESSAGESubscriber SLAVE_MESSAGE

Pub ID 10 Sub ID 10

Pub ID 11Sub ID 11

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Example: Emergency stop

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Example: Guard door monitoring

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Example: Emergency stop and protective door

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Questions?

Questions?

Questions?

Questions?

Questions?

Questions?

Questions regarding TwinSAFE?