BECKHOFF EK1914 User Manual

Operating instructions for

EK1914

TwinSAFE Bus Coupler with two fail-safe inputs and

two fail-safe outputs

Version: 1.1.1

Date: 2015-03-11

Table of contents

Table of contents

1	Foreword			3
	1.1	Notes on the manual		3
		1.1.1	Disclaimer	3
		1.1.2	Brands	3
		1.1.3	Patents	3
		1.1.4	Copyright	3
		1.1.5	Delivery conditions	3
	1.2	Safety instructions		4
		1.2.1	Delivery state	4
		1.2.2 Operator's obligation to exercise diligence		4
		1.2.3 Description of safety symbols		5
		1.2.4 Origin of the document		5
		1.2.5	Documentation issue status	6
2	System description			7
	2.1	The Beckhoff Bus Terminal system		7
		2.1.1	Bus Coupler	8
		2.1.2	Bus Terminals	9
		2.1.3	E-bus	9
		2.1.4	Power contacts	9
	2.2	TwinSAFE		10
		2.2.1 The I/O construction kit is extended safely		10
		2.2.2	Safety concept	10
		2.2.3 EL1904, EL2904 - Bus Terminals with 4 fail-safe inputs or outputs		11
		2.2.4	EL6900 - TwinSAFE logic terminal	11
		2.2.5 The fail-safe principle (Fail Stop)		11
3	Product description			12
	3.1	General description		12
	3.2	Intended use		13
	3.3	Technical data		14
	3.4	Safety parameters		15
	3.5	Dimensions		16

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Table of contents

4	Operation			17
	4.1	Installation		17
		4.1.1	Safety instructions	17
		4.1.2	Transport / storage	17
		4.1.3	Mechanical installation	18
		4.1.4	Electrical installation	20
		4.1.5 Wire cross sections (HD)		23
		4.1.6 Pin assignment of the EK1914		24
		4.1.7	Tested devices	28
	4.3	Configuration of the EK1914 in the TwinCAT System Manager		29
		4.3.1 Inserting a Beckhoff TwinSAFE Bus Coupler		29
		4.3.2 Address settings on the EK1914 TwinSAFE Bus Coupler		30
		4.3.3 Entering a TwinSAFE address and parameters in the System Manager		31
	4.4	Diagnostics		35
		4.4.1	Diagnostic LEDs	35
		4.4.2	Diagnostic objects	37
		4.4.3 Possible causes of diagnostic messages		39
	4.5	Maintenance		41
		4.5.1	Cleaning	41
		4.5.2	Service life	41
	4.6	Decommissioning		42
		4.6.1	Disposal	42
5	Appendix			43
	5.1	Beckhoff Support and Service		43
		5.1.1 Beckhoff branches and partner companies Beckhoff Support		43
		5.1.2	Beckhoff company headquarters	43
	5.2	Certificate		44

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EK1914

Foreword

1 Foreword

1.1 Notes on the manual

This description is only intended for the use of trained specialists in control and automation technology familiar with the applicable national standards. It is essential that the following notes and explanations are followed when installing and commissioning these components.

The responsible staff must ensure that the application or use of the products described satisfy all the safety requirements, including all the relevant laws, regulations, guidelines and standards.

1.1.1 Disclaimer

This documentation has been prepared with care. The products described are, however, constantly under development. For this reason, the documentation may not always have been fully checked for consistency with the performance data, standards or other characteristics described.

If it should contain technical or editorial errors, we reserve the right to make changes at any time and without notice.

No claims for the modification of products that have already been supplied may be made on the basis of the data, diagrams and descriptions in this documentation.

1.1.2 Brands

Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE® and XFC® are registered trademarks of and licensed by Beckhoff Automation GmbH.

The use by third parties of other brand names or trademarks contained in this documentation may lead to an infringement of the rights of the respective trademark owner.

1.1.3 Patents

The EtherCAT technology is patent protected, in particular by the following applications and patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with the corresponding applications and registrations in various other countries.

The TwinCAT technology is patent protected, in particular by the following applications and patents: EP0851348, US6167425 with the corresponding applications and registrations in various other countries.

1.1.4 Copyright

© Beckhoff Automation GmbH & Co. KG.

The copying, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited. Offenders shall be held liable for damages. All rights conferred by patent grant or registration of a utility model or registered design are reserved.

1.1.5 Delivery conditions

In addition, the general delivery conditions of the company Beckhoff Automation GmbH & Co. KG apply.

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Foreword

1.2 Safety instructions

1.2.1 Delivery state

All the components are supplied in particular hardware and software configurations appropriate for the application. 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 section Product description);

∙the TwinSAFE products are only operated in sound condition and in working order (see chapter

Cleaning).

∙the TwinSAFE products are operated only by suitably qualified and authorized personnel.

∙the personnel is instructed regularly about relevant occupational safety and environmental protection aspects, and is familiar with the operating instructions and in particular the safety instructions contained herein.

∙the operating instructions are in good condition and complete, and always available for reference at the location where the TwinSAFE products are used.

∙none of the safety and warning notes attached to the TwinSAFE products are removed, and all notes remain legible.

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EK1914

Foreword

1.2.3 Description of safety symbols

The following safety symbols are used in these operating instructions. They are intended to alert the reader to the associated safety instructions.

		Serious risk of injury!
	DANGER	Failure to follow the safety instructions associated with this symbol directly endangers
		the life and health of persons.
		Caution - Risk of injury!
	WARNING	Failure to follow the safety instructions associated with this symbol endangers the life
		and health of persons.
		Personal injuries!
	CAUTION	Failure to follow the safety instructions associated with this symbol can lead to injuries
		to persons.
		Damage to the environment or devices
	Attention	Failure to follow the instructions associated with this symbol can lead to damage to the
		environment or equipment.

Tip or pointer

This symbol indicates information that contributes to better understanding.

Note

1.2.4 Origin of the document

These operating instructions were originally written in German. All other languages are derived from the German original.

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Foreword

1.2.5 Documentation issue status

Version	Comment
1.1.1	∙	Certificate updated
1.1.0	∙	Revision levels added
	∙	Company address amended
	∙	DateCode description added
	∙ HFT and element classification added
1.0.1	∙	Certificate added
1.0.0	∙	First released version

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EK1914

System description

2 System description

2.1 The Beckhoff Bus Terminal system

The Beckhoff Bus Terminal system is used for decentralized connection of sensors and actuators to a control system. The Beckhoff Bus Terminal system components are mainly used in industrial automation and building management applications. In its minimum configuration, a bus station consists of a Bus Coupler or a Bus Terminal Controller and Bus Terminals connected to it. The Bus Coupler forms the communication 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 terminals via the screwless Cage Clamp© connection system.

In order to accommodate the wide range of different communication standards encountered in industrial automation, Beckhoff offers Bus Couplers for a number of common bus systems (e.g. EK1100 for EtherCAT).

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System description

2.1.1 Bus Coupler

Mechanical data

Mechanical data	Bus Coupler
Material	polycarbonate, polyamide (PA6.6).
Dimensions (W x H x D)	44 mm x 100 mm x 68 mm
Installation	on 35 mm mounting rail (EN50022) with locking
Attachable by	double slot and key connection

Connection technology

Connection	Bus Coupler
technology
Wiring	single-wire conductors: direct plug-in technique
	fine-wire conductor and wire end sleeve: spring actuation by screwdriver
Connection cross-	single-wire:	0.08 to 1.5 mm²
section	fine-wire:	0.25 to 1.5 mm²
	wire end sleeve:	0.14 to 0.75 mm²
Fieldbus connection	EtherCAT
Rated voltage	24 VDC

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System description

2.1.2 Bus Terminals

Mechanical data

	Mechanical data		Bus Terminal
	Material		polycarbonate, polyamide (PA6.6).
	Dimensions (W x H x D)		12 mm x 100 mm x 68 mm or 24 mm x 100 mm x 68 mm
	Installation		on 35 mm mounting rail (EN50022) with locking
	Attachable by		double slot and key connection

Connection technology

Connection technology	Bus Terminal
Wiring	cage Clamp® spring-loaded system
Connection cross-section	0.08 mm2 ... 2.5 mm2, stranded wire, solid wire
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 three power contacts. Terminal strip can be split into galvanically isolated groups by means of potential feed terminals as required. The power feed terminals play no part in the control of the terminals, and can be inserted at any locations within the terminal strip.

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System description

2.2 TwinSAFE

2.2.1 The I/O construction kit is extended safely

With the TwinSAFE Terminals, Beckhoff offers the option of simply expanding the proven Bus Terminal system, and to transfer the complete cabling for the safety circuit into the already existing fieldbus cable. Safe signals can be mixed with standard signals without restriction. This saves design effort, installation and material. Maintenance is simplified significantly through faster diagnosis and simple replacement of only a few components.

The new ELx9xx series Bus Terminals only include three basic functionalities: digital inputs EL19xx, digital outputs EL29xx and a logic unit EL6900. For a large number of applications, all sensors and actuators can be wired on these Bus Terminals. The required logical link of the inputs and the outputs is handled by the EL6900. For small to medium-sized configurations, the tasks of a fail-safe PLC can thus be handled within the Bus Terminal system.

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

∙Logical link of the I/Os in the EL6900 TwinSAFE logic terminal

∙Safety-relevant networking of machines via bus systems

TwinSAFE protocol (Fail Safe over EtherCAT - 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 TwinSAFE configurator

∙Configuration of the TwinSAFE system via the TwinCAT System Manager

∙System Manager for editing and displaying all bus parameters

∙Certified function blocks such as emergency stop, operation mode, etc.

∙Simple handling

∙Typical function blocks for machine safety

∙Any bus connection with the EL6900 TwinSAFE logic terminal

TwinSAFE logic Bus Terminal EL6900

∙Link unit between TwinSAFE input and output terminals

∙Configuration of a simple, flexible, cost-effective, decentralized safety controller

∙No safety requirements for higher-level control system

∙TwinSAFE enables networks with up to 65535 TwinSAFE devices

∙TwinSAFE logic terminal can establish up to 128 connections (TwinSAFE connections).

∙Several TwinSAFE logic terminals are cascadable in a network

∙Safety functions such as emergency stop, protective door etc. are already included

∙Suitable for applications up to SIL 3 according to IEC 61508:2010 and DIN EN ISO 13849-1:2006 (Cat 4, PL e).

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System description

TwinSAFE digital input (EL1904) and output terminal (EL2904)

∙All current safety sensors can be connected

∙Operation with a TwinSAFE logic terminal

∙EL1904 with 4 fail-safe inputs for sensors (24 VDC) with floating contacts

∙EL2904 with four safe channels for actuators (24 VDC, 0.5 A per channel)

∙Conforming to IEC 61508:2010 SIL 3 and DIN EN ISO 13849-1:2006 (Cat 4, PL e) requirements.

2.2.3 EL1904, EL2904 - Bus Terminals with 4 fail-safe inputs or outputs

The EL1904 and EL2904 Bus Terminals enable connection of common safety sensors and actuators. They are operated with the EL6900 TwinSAFE logic terminal. The TwinSAFE logic terminal is the link unit between the TwinSAFE input and output terminals. 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 to the safety requirements of his application.

2.2.4 EL6900 - TwinSAFE logic terminal

The TwinSAFE logic terminal is the link unit between the TwinSAFE input and output terminals. The EL6900 meets the requirements of IEC 61508:2010 SIL 3 and DIN EN ISO 13849-1:2006 (Cat 4, PL e).

2.2.5 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. The safe state is always the switched off and wattless state.

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Product description

3 Product description

3.1 General description

EK1914 - TwinSAFE Bus Coupler with two fail-safe inputs and two fail-safe outputs

The EK1914 is an EtherCAT Bus Coupler with 4 standard inputs, 4 standard outputs, and 2 fail-safe inputs and 2 fail-safe outputs.

The TwinSAFE Bus Coupler has the usual design of an EtherCAT coupler.

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