1 twinsafe new automation technology. 2 twinsafe beckhoff twinsafe: safety and standard i/o in one...
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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.
4TwinSAFE
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
5TwinSAFE
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
6TwinSAFE
Plant concatenation with TwinSAFE
Machine „A“ Machine „B“ Machine „C“
TwinSAFE data TwinSAFE data
7TwinSAFE
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..)
8TwinSAFE
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
9TwinSAFE
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
10TwinSAFE
- 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
11TwinSAFE
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
12TwinSAFE
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
13TwinSAFE
Communication between TwinSAFE terminals
KL6904
KL1904
TwinSAFE message from KL6904 to KL1904 (Master-Message)
TwinSAFE message from KL1904 to KL6904 (Slave-Message)
fieldbus
14TwinSAFE
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.
15TwinSAFE
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.
16TwinSAFE
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)
19TwinSAFE
Step 1: TwinSAFE terminals will be configured in the System Manager
TwinSAFE busterminal
standard busterminal
23TwinSAFE
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.
26TwinSAFE
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..
27TwinSAFE
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)
28TwinSAFE
Connections
Connections will be created automatically when an input or output is used in a function block configuration inside that group
31TwinSAFE
Diagnosis KL6904
Diagnosis:
-Internal temperatures
-Error codes of µC1
-Error codes of µC2
32TwinSAFE
Diagnosis TwinSAFE group
Diagnosis online:-Group state-Run/Stop of group-ErrAck Signal-Error at one of the FBs-Communication error-Output error
34TwinSAFE
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
35TwinSAFE
Diagnosis for TwinSAFE connections
Diagnosis:-Connection number-Connection type
- Master- Slave
-State -Diagnosis flags
36TwinSAFE
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
38TwinSAFE
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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Settings of TwinSAFE structure
S-address of the communication partner must match
Watchdog time must be identical on both sides of the connection
43TwinSAFE
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.
46TwinSAFE
User administration and version history
Create user…
Save TwinSAFE project…
Stored in the history…
51TwinSAFE
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