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EK1960-2600
Operating Instructions Manual
145 pgs7.47 Mb1
Table of contents
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Beckhoff EK1960-2600, EK1960-2608 Operating Instructions Manual

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Operating Instructions for
EK1960
TwinSAFE Compact Controller
Version: Date:
1.3.1 2019-01-28

Table of contents

Table of contents
1 Foreword ....................................................................................................................................................7
1.1 Notes on the documentation..............................................................................................................7
1.2 Safety instructions .............................................................................................................................8
1.2.1 Delivery state ..................................................................................................................... 8
1.2.2 Operator's obligation to exercise diligence ........................................................................ 8
1.2.3 Description of safety symbols ............................................................................................ 9
1.3 Documentation issue status ............................................................................................................10
1.4 Version history of the TwinSAFE product........................................................................................11
2 System description TwinSAFE...............................................................................................................12
2.1 Extension of the Beckhoff I/O system with safety functions ............................................................12
2.2 Safety concept.................................................................................................................................12
3 Product description.................................................................................................................................13
3.1 General description .........................................................................................................................13
3.2 Product designations .......................................................................................................................14
3.3 Inputs and outputs of the EK1960 ...................................................................................................15
3.4 Connection technology ....................................................................................................................18
3.4.1 Power supply spring contact strip .................................................................................... 18
3.4.2 Input and output spring contact strip................................................................................ 18
3.4.3 Relay contact spring contact strip.................................................................................... 18
3.5 Intended use....................................................................................................................................19
3.6 Technical data .................................................................................................................................20
3.6.1 Technical data – relay option........................................................................................... 22
3.7 Safety parameters ...........................................................................................................................24
3.8 Error response times .......................................................................................................................26
3.9 Characteristic curve of the inputs ....................................................................................................27
3.10 Test pulses for the outputs ..............................................................................................................27
3.11 Load characteristic curve – inductive load.......................................................................................29
3.12 Block diagram of the EK1960 ..........................................................................................................30
3.13 Address setting of the TwinSAFE compact controller .....................................................................31
3.14 Dimensions......................................................................................................................................32
3.15 Wiring examples ..............................................................................................................................32
3.15.1 Inputs and outputs ........................................................................................................... 32
3.15.2 Clocked signals................................................................................................................ 36
4 Operation..................................................................................................................................................37
4.1 Environmental conditions ................................................................................................................37
4.2 Installation ......................................................................................................................................37
4.2.1 Safety instructions ........................................................................................................... 37
4.2.2 Transport / storage .......................................................................................................... 37
4.2.3 Mechanical installation..................................................................................................... 37
4.2.4 Electrical installation ........................................................................................................ 40
4.3 Configuration of the controller in TwinCAT......................................................................................42
4.3.1 Configuration requirements ............................................................................................. 42
4.3.2 Insertion of a controller .................................................................................................... 42
Table of contents
4.3.3 Creating a safety project in TwinCAT3 ........................................................................... 43
4.3.4 Downloading the safety application ................................................................................. 75
4.4 Info data...........................................................................................................................................79
4.4.1 Info data for the connection ............................................................................................ 79
4.4.2 Info data for function blocks............................................................................................. 80
4.4.3 Info data for the TwinSAFE group ................................................................................... 81
4.4.4 Info data for the device .................................................................................................... 82
4.5 Version history.................................................................................................................................83
4.6 User Administration .........................................................................................................................84
4.7 Backup/Restore ...............................................................................................................................86
4.8 Export/import of the safety project...................................................................................................90
4.9 Diag History tab ...............................................................................................................................92
4.10 TwinSAFE SC configuration ............................................................................................................93
4.11 Customizing / disabling TwinSAFE groups......................................................................................97
4.12 Saving the analog group inputs persistently..................................................................................100
4.13 New features in TC3.1 Build 4022.................................................................................................101
4.13.1 Group status .................................................................................................................. 101
4.13.2 Online view group ports................................................................................................. 103
4.13.3 Group templates ............................................................................................................ 103
4.13.4 Networks collapsable..................................................................................................... 103
4.13.5 Subfolder Alias Devices................................................................................................. 104
4.13.6 Goto linked element....................................................................................................... 105
4.13.7 Path view to linked signal .............................................................................................. 105
4.13.8 Multiline comments........................................................................................................ 106
4.13.9 Names of Alias Devices in the process image............................................................... 107
4.13.10 Project settings - Verification ......................................................................................... 108
4.13.11 Displaying the project size............................................................................................. 108
4.13.12 Copy and Paste for FBs and comments........................................................................ 109
4.13.13 Global settings in Visual Studio ..................................................................................... 111
4.13.14 Sorting ........................................................................................................................... 113
4.13.15 Direct mapping of local I/Os........................................................................................... 115
4.13.16 Backup/Restore settings................................................................................................ 116
4.13.17 Multiple download.......................................................................................................... 117
4.14 Diagnostics ....................................................................................................................................120
4.14.1 Diagnostic LEDs ............................................................................................................ 120
4.14.2 Status LEDs................................................................................................................... 122
4.14.3 Diagnostic objects.......................................................................................................... 123
4.14.4 Cycle time of the safety project...................................................................................... 124
4.14.5 Diagnosis History........................................................................................................... 125
4.15 Project design limits of the EK1960...............................................................................................128
4.16 Behavior when restarting...............................................................................................................128
4.17 Sync-Manager Configuration.........................................................................................................129
4.18 Reaction times of local signals ......................................................................................................131
4.19 TwinSAFE reaction times ..............................................................................................................131
4.20 Reaction times Bumper mode .......................................................................................................133
4.21 Reaction times ambient conditions................................................................................................133
EK19604 Version: 1.3.1
Table of contents
4.22 Maintenance ..................................................................................................................................133
4.22.1 Cleaning......................................................................................................................... 133
4.23 Service life .....................................................................................................................................134
4.23.1 Decommissioning .......................................................................................................... 135
4.24 Firmware update of TwinSAFE products.......................................................................................136
5 Appendix ................................................................................................................................................139
5.1 Support and Service ......................................................................................................................139
5.2 Certificates.....................................................................................................................................140
Table of contents
EK19606 Version: 1.3.1
Foreword

1 Foreword

1.1 Notes on the documentation

Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who are 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 requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Origin of the document
This documentation was originally written in German. All other languages are derived from the German original.
Currentness
Please check whether you are using the current and valid version of this document. The current version can be downloaded from the Beckhoff homepage at http://www.beckhoff.com/english/download/twinsafe.htm. In case of doubt, please contact Technical Support [}139].
Product features
Only the product features specified in the current user documentation 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 the right to revise and change the documentation at any time and without prior announcement. 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.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCATP®, SafetyoverEtherCAT®, TwinSAFE®, XFC® and XTS® are registered trademarks of and licensed by Beckhoff Automation GmbH. Other designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with corresponding applications or registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent applications and patents: EP0851348, US6167425 with corresponding applications or registrations in various other countries.
Foreword
EtherCAT® and Safety over EtherCAT® are registered trademarks and patented technologies, licensed by Beckhoff Automation GmbH, Germany.
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany. The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization are prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
Delivery conditions
In addition, the general delivery conditions of the company Beckhoff Automation GmbH & Co. KG apply.

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 chapter Product description);
• the TwinSAFE products are only operated in sound condition and in working order.
• 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.
EK19608 Version: 1.3.1

1.2.3 Description of safety symbols

In these operating instructions the following instructions are used. These instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow this safety instruction directly endangers 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.
Foreword
Tip or pointer
This symbol indicates information that contributes to better understanding.
Foreword

1.3 Documentation issue status

Version Comment
1.3.1 • Layout corrected at chapter Sample program for parameterization
1.3.0 • Description of Module Fault Link active parameter added
• Description of Multiple Download added
• Description of input and output signals expanded
• Description of error response times added
• Version history of TwinSAFE product added
• Description of firmware update added
1.2.0 • Description of inductive load and free-wheeling diode changed
• New features TwinCAT 3.1 Build 4022 added
• Diagnosis history described
• Reaction times BumperMode and ambient conditions added
• Description TwinSAFE SC updated
• Description of Behavior when restarting added
• Project design limits adjusted
• Note to the permissible loads on the relay contacts added
1.1.0 • Note to the input and output process image added
• Description for Sync Manager configuration added
• TwinSAFE SC description updated
1.0.0 • Certificate added
• General document revision
• Description of input module 9 and 10 updated
0.7.0 • Load characteristics for inductive loads added
• Backup/Restore flow chart added
0.6.1 • User administration screenshots updated
• State and Diag of the TwinSAFE group updated
0.6.0 • Safety parameters adopted from review report
0.5.0 • Safety parameters revised
• Parameter values revised
• Diag messages added
0.4.0 • Safety concept requirements for the manual implemented
0.3.0 • Update of the designation of the contact points
• Addendum: illustration of the TwinSAFE compact controller without relay option
0.2.0 • Extension of the general description
• Description of diagnostic and status LEDs added
0.1.0 • Migration, layout adaptation
EK196010 Version: 1.3.1
Foreword

1.4 Version history of the TwinSAFE product

This version history lists the releases of the software and hardware versions. A description of the respective changes to the previous version is also listed.
Updated hardware and software
The TwinSAFE products are subject to a cyclical revision. We reserve the right to revise and change the TwinSAFE products at any time and without notice.
These hardware and/or software changes do not give rise to any claims for changes to products that have already been delivered.
A description of how a firmware update (software) can be carried out can be found in the chapter Firmware update of TwinSAFE products [}136].
Date SW-Version HW-Version Changes
2017-05-02 01 00 • First Release 2017-07-14 02 01 • Optimized safety mat function
• Added support for backup/restore mode
• Protective circuit of the outputs changed
2018-09-19 03 01 • Local logic projects can now also be created without a linked
RUN signal.
• Time stamp for diagnostic messages corrected.
• FB Muting: After an FB error in the backwards operating mode, the FB error can be acknowledged without restarting the TwinSAFE group.
• An error acknowledgement is now required after a user has logged in to the Logic without deleting the project.
• Support of Module Fault Link active parameter added.
• Firmware and vendor data CRCs can be read out in CoE objects.
System description TwinSAFE

2 System description TwinSAFE

2.1 Extension of the Beckhoff I/O system with safety functions

The TwinSAFE products from Beckhoff enable convenient expansion of the Beckhoff I/O system with safety components, and integration of all the cabling for the safety circuit within the existing fieldbus cable. Safe signals can be mixed with standard signals as required. The transfer of safety-related TwinSAFE telegrams is handled by the standard controller. Maintenance is simplified significantly thanks to faster diagnosis and simple replacement of components.
The following basic functionalities are included in the TwinSAFE components: digital inputs (e.g. EL19xx, EP1908), digital outputs (e.g. EL29xx), drive components (e.g. AX5805) and logic units (e.g. EL6900, EL6910). For a large number of applications, the complete safety sensor and actuator technology can be wired on these components. The required logical link of the inputs and the outputs is handled by the EL69xx. In addition to Boolean operations, the EL6910 now also enables analog operations.

2.2 Safety concept

TwinSAFE: Safety and I/O technology in one system
• Extension of the familiar Beckhoff I/O system with TwinSAFE components
• Safe and non-safe components can be combined as required
• Logical link of the I/Os in the EL69xx TwinSAFE logic terminal
• Suitable for applications up to SIL3 according to EN61508:2010 and Cat4, PLe according to ENISO13849-1:2015
• Safety-relevant networking of machines via bus systems
• In the event of an error, all TwinSAFE components always switch to the wattless and therefore safe state
• No safety requirements for the higher-level standard TwinCAT system
Safety over EtherCAT protocol (FSoE)
• Transfer of safety-relevant data via any media (“genuine black channel”)
• TwinSAFE communication via fieldbus systems such as EtherCAT, Lightbus, PROFIBUS, PROFINET or Ethernet
• IEC 61508:2010 SIL 3 compliant
• FSoE is IEC standard (IEC 61784-3-12) and ETG standard (ETG.5100)
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.
CAUTION
Safe state
For all TwinSAFE components the safe state is always the switched-off, wattless state.
EK196012 Version: 1.3.1
Product description

3 Product description

3.1 General description

EK1960 – TwinSAFE-Compact-Controller
The EK1960 is a TwinSAFE controller with 20 fail-safe inputs and 24 fail-safe outputs. The EK1960-2600 and EK1960-2608 variants feature an additional four relays, each with one make contact.
The EK1960 TwinSAFE compact controller is suitable for safety applications up to SIL 3 according to IEC62061 and IEC61508 and up to Cat. 4, PL e according to ENISO13849-1:2015. (See following list for restrictions):
• The single-channel relay output is suitable up to Cat. 2, PL d
• The two-channel relay output (use of two relay contacts in series) is suitable up to Cat. 3, PL d or Cat. 4, PL e, depending on the number of actuations. Cat. 4, PL e requires an actuation at least once per month, Cat. 3, PL d at least once per year.
• The safe input for the safety mat operation mode is limited to Cat. 2, PL d.
Special proof tests are not necessary during the entire lifetime of the EK1960 on account of the high level of diagnostic coverage.
The EK1960 can be used in three different application cases:
• As a stand-alone TwinSAFE compact controller without the use of an EtherCAT network with 20 inputs and 24 outputs. An extension with terminals to the right of the EK1960 on the E-bus is not possible in this operation mode.
• As a TwinSAFE compact controller integrated into an EtherCAT network. The EK1960 can be extended with standard and safety terminals on the E-bus connection and via the EtherCAT network.
• As a TwinSAFE I/O module. The logic on the TwinSAFE compact controller is not used. The coupler can be addressed by a TwinSAFE logic terminal as an I/O module with 20 inputs and 24 outputs.
The inputs of the EK1960 can be used as digital 24 V inputs. They can be fed to the safe input either with static 24 VDC or with a clock from one of the TwinSAFE outputs of the EK1960 or via an external clock source via, for example, a switch contact. Inputs 17 to 20 can additionally be switched to a safety mat operation mode (Bumper Mode On) . Only safety mats operating according to the resistance-change principle are supported. The safety mats can also be cascaded in accordance with the manufacturer's specifications. The inputs can be parameterized in groups of two.
The outputs can be parameterized in groups of four. It is possible to set the mark-to-space-ratio and the activation as a clock source for the safe inputs.
Product description
Fig.1: EK1960-260x TwinSAFE-Compact-Controller
The EK1960 without relay option has a dummy cap on X4.
Fig.2: EK1960-000x TwinSAFE compact controller without relay option

3.2 Product designations

Product designation Description
EK1960-0000 EK1960 with EtherCAT RJ45 connections – without relay option EK1960-0008 EK1960 with EtherCAT M8 connections – without relay option EK1960-2600 EK1960 with EtherCAT RJ45 connections – with four potential-free contacts
(NO) EK1960-2608 EK1960 with EtherCAT M8 connections – with four potential-free contacts (NO) ZS2003-0001 Spare part, power supply spring contact strip, 4-pole
Contact spacing 3.5 mm ZS2003-0002 Spare part, input/output spring contact strip, 10-pole
Contact spacing 3.5 mm ZS2003-0003 Spare part, relay contact spring contact strip, 10-pole
Contact spacing 5.0 mm (EK1960-260x only)
EK196014 Version: 1.3.1
Product description

3.3 Inputs and outputs of the EK1960

NOTE
Fuses for the EK1960
Fuses must be provided for the power supplies of the EK1960 2 A each for US and UP (X3) and 5 A each for UP1 to UP6 (X5, X7, X9).
plug contact Name Description
EtherCAT (X1) EtherCAT 1 EtherCAT connection 1
(RJ45 or M8)
EtherCAT (X2) EtherCAT 2 EtherCAT connection 2
(RJ45 or M8)
Power (X3) 1 U
s
2 0V GND 3 U
p
4 0V GND
Relais (X4)
1 4.1 Input to Relay 1 make contact
(EK1960-260x only)
2 4.2 Input to Relay 2 make contact
3 4.3 Input to Relay 3 make contact
4 4.4 Input to Relay 4 make contact
5 n.c. not used 6 n.c. not used 7 4.5 Output to Relay 1 make contact
8 4.6 Output to Relay 2 make contact
9 4.7 Output to Relay 3 make contact
10 4.8 Output to Relay 4 make contact
Output (X5) 1 5.1 Output 1 from U
2 5.2 Output 2 from U
3 5.3 Output 3 from U
4 5.4 Output 4 from U
5 U
P1
6 5.5 Output 5 from U
7 5.6 Output 6 from U
8 5.7 Output 7 from U
9 5.8 Output 8 from U
10 U
P2
Control voltage 24 VDC (SELV/PELV) Supply of power for internal logic and E-bus connection
Peripheral voltage 24VDC (SELV/PELV) Supply of power for relays and inputs in the safety mat operation mode
(Channel7.FSOUT RelaisModule.Channel1.Output)
(Channel7.FSOUT RelaisModule.Channel2.Output)
(Channel7.FSOUT RelaisModule.Channel3.Output)
(Channel7.FSOUT RelaisModule.Channel4.Output)
(Channel7.FSOUT RelaisModule.Channel1.Output)
(Channel7.FSOUT RelaisModule.Channel2.Output)
(Channel7.FSOUT RelaisModule.Channel3.Output)
(Channel7.FSOUT RelaisModule.Channel4.Output)
(Channel1.FSOUT Module 1.Channel1.Output)
(Channel1.FSOUT Module 1.Channel2.Output)
(Channel1.FSOUT Module 1.Channel3.Output)
(Channel1.FSOUT Module 1.Channel4.Output) Peripheral voltage U
(Channel2.FSOUT Module 2.Channel1.Output)
(Channel2.FSOUT Module 2.Channel2.Output)
(Channel2.FSOUT Module 2.Channel3.Output)
(Channel2.FSOUT Module 2.Channel4.Output) Peripheral voltage U
P1
P1
P1
P1
24 VDC (SELV/PELV)
P1
P2
P2
P2
P2
24V
P2
DC
(SELV/PELV)
Product description
plug contact Name Description
Input (X6) 1 6.1 Input 1
2 6.2 Input 2
3 6.3 Input 3
4 6.4 Input 4
5 6.5 Input 5
6 6.6 Input 6
7 6.7 Input 7
8 6.8 Input 8
9 6.9 Input 9
10 6.10 Input 10
Output (X7) 1 7.1 Output 9 from U
2 7.2 Output 10 from U
3 7.3 Output 11 from U
4 7.4 Output 12 from U
5 U
P3
6 7.5 Output 13 from U
7 7.6 Output 14 from U
8 7.7 Output 15 from U
9 7.8 Output 16 from U
10 U
P4
Input (X8) 1 8.1 Input 11
2 8.2 Input 12
3 8.3 Input 13
4 8.4 Input 14
5 8.5 Input 15
6 8.6 Input 16
7 8.7 Input 17
8 8.8 Input 18
9 8.9 Input 19
10 8.10 Input 20
(Channel8.FSIN Module 1.Channel1.Input)
(Channel8.FSIN Module 1.Channel2.Input)
(Channel9.FSIN Module 2.Channel1.Input)
(Channel9.FSIN Module 2.Channel2.Input)
(Channel10.FSIN Module 3.Channel1.Input)
(Channel10.FSIN Module 3.Channel2.Input)
(Channel11.FSIN Module 4.Channel1.Input)
(Channel11.FSIN Module 4.Channel2.Input)
(Channel12.FSIN Module 5.Channel1.Input)
(Channel12.FSIN Module 5.Channel2.Input)
(Channel3.FSOUT Module 3.Channel1.Output)
(Channel3.FSOUT Module 3.Channel2.Output)
(Channel3.FSOUT Module 3.Channel3.Output)
(Channel3.FSOUT Module 3.Channel4.Output) Peripheral voltage U
(Channel4.FSOUT Module 4.Channel1.Output)
(Channel4.FSOUT Module 4.Channel2.Output)
(Channel4.FSOUT Module 4.Channel3.Output)
(Channel4.FSOUT Module 4.Channel4.Output) Peripheral voltage U
(Channel13.FSIN Module 6.Channel1.Input)
(Channel13.FSIN Module 6.Channel2.Input)
(Channel14.FSIN Module 7.Channel1.Input)
(Channel14.FSIN Module 7.Channel2.Input)
(Channel15.FSIN Module 8.Channel1.Input)
(Channel15.FSIN Module 8.Channel2.Input)
(digital - Digital Mode On, safety mat operation mode (resistance change) - Bumper Mode On) (Channel16.FSIN Module 9.Channel1.Input)
(digital - Digital Mode On, safety mat operation mode (resistance change) - Bumper Mode On) (Channel16.FSIN Module 9.Channel2.Input)
(digital - Digital Mode On, safety mat operation mode (resistance change) - Bumper Mode On) (Channel17.FSIN Module 10.Channel1.Input)
(digital - Digital Mode On, safety mat operation mode (resistance change) - Bumper Mode On) (Channel17.FSIN Module 10.Channel2.Input)
P3
P3
P3
P3
24V
24V
(SELV/PELV)
DC
(SELV/PELV)
DC
P3
P4
P4
P4
P4
P4
EK196016 Version: 1.3.1
Product description
plug contact Name Description
Output (X9) 1 9.1 Output 17 from U
(Channel5.FSOUT Module 5.Channel1.Output)
2 9.2 Output 18 from U
(Channel5.FSOUT Module 5.Channel2.Output)
3 9.3 Output 19 from U
(Channel5.FSOUT Module 5.Channel3.Output)
4 9.4 Output 20 from U
(Channel5.FSOUT Module 5.Channel4.Output)
5 U
P5
Peripheral voltage U
6 9.5 Output 21 from U
(Channel6.FSOUT Module 6.Channel1.Output)
7 9.6 Output 22 from U
(Channel6.FSOUT Module 6.Channel2.Output)
8 9.7 Output 23 from U
(Channel6.FSOUT Module 6.Channel3.Output)
9 9.8 Output 24 from U
(Channel6.FSOUT Module 6.Channel4.Output)
10 U
P6
Peripheral voltage U
P5
P5
P5
P5
24V
24V
(SELV/PELV)
DC
(SELV/PELV)
DC
P5
P6
P6
P6
P6
P6
NOTE
Protected wiring
If the wiring of the outputs or the connected actuators leaves the control cabinet, the user must ensure that the wiring is protected.
WARNING
Active loads
The use of active loads (with their own power supply) is not permissible unless the manufacturer of the load ensures the non-reactivity of the power supply to the control signal.
DANGER
Clocked signals within a sheathed cable
Are clocked signals of different output modules used within a sheathed cable, a failure of a module, such as cross-circuit or external power supply must lead to a switch off of all these modules. This switch off must be performed by the user program.
From firmware version 03 and revision -0021 the parameter Module Fault Link active is available. If the pa­rameter is set to TRUE for all modules involved, all these modules are set to the error state in the event of a module error. This parameter is set to TRUE by default.
Product description

3.4 Connection technology

3.4.1 Power supply spring contact strip

The power supply spring contact strip is required for the X3 connection.
Item number ZS2003-0001
Number of contacts 4 Contact spacing 3.5 mm Connection methods Spring-loaded terminal technology Wire cross-section (solid-wire) 0.2 – 1.5 mm² Wire cross-section (fine-wire) 0.2 – 1.5 mm² Conductor cross-sectional area – fine wire (with wire-
end ferrules with plastic collars) Conductor cross-sectional area – fine wire (with wire-
end ferrules without plastic collars) Strip length 8 - 9 mm
0.25 – 0.75 mm²
0.25 – 1.5 mm²

3.4.2 Input and output spring contact strip

The input and output spring contact strip is required for the connection X5 to X9.
Item number ZS2003-0002
Number of contacts 10 Contact spacing 3.5 mm Connection methods Spring-loaded terminal technology Wire cross-section (solid-wire) 0.2 – 1.5 mm² Wire cross-section (fine-wire) 0.2 – 1.5 mm² Conductor cross-sectional area – fine wire (with wire-
end ferrules with plastic collars) Conductor cross-sectional area – fine wire (with wire-
end ferrules without plastic collars) Strip length 8 - 9 mm
0.25 – 0.75 mm²
0.25 – 1.5 mm²

3.4.3 Relay contact spring contact strip

The relay contact spring contact strip is required for the connection X4 (EK1960-260x only).
Item number ZS2003-0003
Number of contacts 10 Contact spacing 5.0 mm Connection methods Spring-loaded terminal technology Wire cross-section (solid-wire) 0.2 – 2.5 mm² Wire cross-section (fine-wire) 0.2 – 2.5 mm² Conductor cross-sectional area – fine wire (with wire-
end ferrules with plastic collars) Conductor cross-sectional area – fine wire (with wire-
end ferrules without plastic collars) Strip length 9 - 10 mm
0.25 – 1.5 mm²
0.25 – 2.5 mm²
EK196018 Version: 1.3.1
Product description

3.5 Intended use

WARNING
Caution - Risk of injury!
The TwinSAFE compact controller may only be used for the purposes described below!
The TwinSAFE compact controller expands the application range of the Beckhoff EtherCAT system by functions that enable it to be used in the field of machine safety as well. The TwinSAFE compact controller is designed for machine safety functions and the directly associated industrial automation tasks. It is therefore approved only for applications with a defined fail-safe state. This safe state is the wattless state.
The EK1960 TwinSAFE compact controller is suitable for operation as
• Stand-alone Safety Controller
• a safety controller within an EtherCAT network
• a safety I/O device within an EtherCAT network with, for example, an EL6910 as TwinSAFE Master
WARNING
System limits
The TÜV-Süd certificate applies to the EK1960, the function blocks available in it, the documentation and the engineering tool. Approved engineering tools are TwinCAT 3.1, TwinSAFE Loader and CODESYS Safety for EtherCAT Safety Module. Any deviations from the procedures or tools, particularly externally generated xml files for TwinSAFE import or externally generated automatic project creation procedures, are not covered by the certificate.
WARNING
Power supply
The TwinSAFE compact controller must be supplied with 24 VDC by an SELV/PELV power supply unit with an output voltage limit U
of 36 VDC. Failure to observe this can result in a loss of security.
max
WARNING
Commissioning test
Before the EK1960 can be used for the safety task, the user must carry out a commissioning test so that sensor and actuator wiring errors can be ruled out.
CAUTION
Note the Machinery Directive
The TwinSAFE compact controller may only be used in machines within the meaning of the Machinery Di­rective.
CAUTION
Ensure traceability
The buyer has to ensure the traceability of the device via the serial number.
Product description

3.6 Technical data

Product designation EK1960
Number of inputs 20 Number of outputs 24 (+ 4 optional relay outputs) Cable length between sensor and input 30 m (if cables with a cross-sectional area of 0.75mm²
are used)
Cable length between output and actuator 30 m (if cables with a cross-sectional area of 0.75mm²
are used) Minimum/maximum logic cycle time approx. 1 ms / according the project size Fault response time ≤ watchdog times Watchdog time min. 2ms, max. 60,000ms Input process image Dynamic, according to the TwinSAFE configuration in
TwinCAT3 Output process image Dynamic, according to the TwinSAFE configuration in
TwinCAT3 Supply voltage (SELV/PELV) 24VDC (–15%/+20%)
Provide a 2 A fuse for US and U E-bus power supply (5 V) max. 500mA
(In the case of higher current consumption,
P
please use the EL9410 power feed terminals in addition!) Signal voltage inputs
see Characteristic curve of the inputs [}27] Output module (4 channels) 24VDC (–15% / +20%) SELV/PELV for UP1 to U
max. 2A per channel
min. 30 mA with a test pulse length of 400 µs and
resistive load
Simultaneity factor 50% per module
Provide 5 A fuse for each U
Px
Diagnostic thresholds:
>4V -> high signal is detected
<2.4V -> low signal is detected Permissible actuators
• inductive loads (see also Load characteristic curve – inductive load [}29])
(A free-wheeling diode must be provided on the load)
• resistive loads
• capacitive loads
Current consumption of the modular electronics at 24VDC (without current consumption of sensors/actuators)
US typ. 80 mA UP typ. 2 mA
UP1 to UP6 each typ. 2mA Dimensions (W x H x D) 230.5mmx 100mmx 58.6mm Weight approx.560g (EK1960-260x)/
approx.500g(EK1960-000x) Permissible ambient temperature (operation) -25 °C to +55 °C Permissible ambient temperature (transport/
-40 °C to +70 °C
storage) Permissible 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 atmosphere)
P6
EK196020 Version: 1.3.1
Product description
Product designation EK1960
Climate category according to EN 60721-3-3 3K3
(the deviation from 3K3 is possible only with optimal
environmental conditions and also applies only to the
technical data which are specified differently in this
documentation) Permissible level of contamination
according to EN 60664-1 Inadmissible operating conditions TwinSAFE controllers must not be used under the
Vibration/shock resistance conforms to EN60068-2-6/ EN60068-2-27 EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4 Shocks 15 g with pulse duration 11 ms in all three axes Protection class as per IEC 60529 IP20 Permitted operating environment In the control cabinet or terminal box, with minimum
Correct installation position
Technical approvals CE, TÜV SÜD
level of contamination 2
(comply with the chapter Cleaning [}133])
following operating conditions:
• under the influence of ionizing radiation (exceeding the natural background radiation)
• in corrosive environments
• in an environment that leads to impermissible soiling of the controller
protection class IP54 according to IEC60529 see chapter Installation position and minimum distances
[}38]
NOTE
Protective circuit
No protective circuit is integrated in the output circuit of the EK1960, so it is necessary to provide a free­wheeling diode on the actuator for inductive loads. However, it must be borne in mind that the free-wheeling diode may prolong the switch-off times of the actuator. The protective circuit must limit the induced voltage at the output to an amount of less than 29V. Thus, R/C circuits and varistors are typically unsuitable.
Product description

3.6.1 Technical data – relay option

Product designation EK1960-260x
Contacts 1NO / 1NC Make contact material (NO) AgNi+0.2 µm Au Feedback contact material (NC) AgNi+5 µm Au Coil voltage 24V Maximum continuous current, NO contact
(when used in safety applications)
Maximum switching current (NO contact) 8A Minimum switching current (NO contact) 10mA (AgNi) Switching capacity according to IEC/EN
60947-5-1 AC15 DC13
Switching frequency (maximum) 20 switching cycles / s Response time ≤ 15ms (typically10ms) Release time ≤ 5ms (typically2ms)
DC
DC13 (24VDC) I=2A AC15 (230VAC) I=3A
250VAC/3A 24VDC/2A
NOTE
Allowed loads of the relay option
The potential-free contacts of the relay option (X4) may only be connected to resistive and inductive loads. Capacitive loads are not permissible.
Load limit curve
Fig.3: Load limit curve, make contact
EK196022 Version: 1.3.1
Operating lifetime for contact material AgNi
Product description
Fig.4: Operating lifetime of the AgNi NO contact for DC1, DC13, AC1 and AC15
Reduction factor for inductive loads
Fig.5: Reduction factor for inductive loads
Product description

3.7 Safety parameters

In the following tables the safety parameters are shown separately for inputs, logic and outputs. The PFH values for the inputs, logic and outputs used must be added together for the complete safety loop. The Safety-over-EtherCAT communication is included in the logic part.
General parameters EK1960
Lifetime [a] 20 Prooftest Intervall [a] ­HFT 1 Classification element
2)
1. Special proof tests are not necessary during the entire lifetime of the EK1960 TwinSAFE compact con­troller on account of the high level of diagnostic coverage.
2. Classification according to IEC 61508-2:2010 (see chapters 7.4.4.1.2 and 7.4.4.1.3)
The EK1960 TwinSAFE compact controller can be used for safety-related applications within the meaning of IEC62061:2005/A2:2015 up to SILCL3 and IEC 61508:2010 up to SIL 3 and ENISO13849-1:2015 up to Cat. 4, PL e. (See following note for restrictions):
CAUTION
1)
Type B
EK1960 category and performance level restrictions
• The single-channel relay output is suitable up to Cat. 2, PL d
• The two-channel relay output (use of two relay contacts in series) is suitable up to Cat. 3, PL d or Cat. 4,
PL e, depending on the number of actuations. Cat. 4, PL e requires an actuation at least once per month, Cat. 3, PL d at least once per year.
• The safe input for the safety mat operation mode is limited to Cat. 2, PL d.
Further information on calculating or estimating the MTTFD value from the PFHD value can be found in the TwinSAFE application manual or in ENISO13849-1:2015, TableK.1.
Relay output safety parameters (Cat. 4 – two-channel)
The following table contains the safety parameters for the two-channel relay output. This must be added to the logic and input value to determine the total PFH value.
One actuation of the relay per hour is assumed for the calculation.
Relay output parameters (Cat. 4 – two-channel) Value
PFH
D
PFD
G
MTTF
D
DC
avg
Performance Level PL e Category 4 SIL 3
1.46E-09
1.48E-06 high high
Relay output safety parameters (Cat. 2 – single-channel)
The following table contains the safety parameters for the single-channel relay output. This must be added to the logic and input value to determine the total PFH value.
One actuation of the relay per hour is assumed for the calculation.
EK196024 Version: 1.3.1
Product description
Relay output parameters (Cat. 2 – single-channel) Value
PFH PFD MTTF DC
avg
D
G
D
7.25E-10
6.42E-05 high
high Performance Level PLd Category 2 SIL 2
B
relay option values
10D
Characteristic numbers EK1960-260x
B
value (DC1324 VDC and I
10D
B
value (AD15230 VAC and I
10D
B
value (AD15230 VAC and I
10D
≤2A) 1,500,000 [switching cycles]
max
≤1A) 750,000 [switching cycles]
max
≤3A) 300,000 [switching cycles]
max
Digital input safety parameters
The following table contains the safety parameters for the digital input of the EK1960. This must be added to the logic and input value to determine the total PFH value.
Digital input parameters Value
PFH PFD MTTF DC
avg
D
G
D
6.4E-11
6.1E-06
high
high Performance Level PL e Category 4 SIL 3
Safety mat input safety parameters
The following table contains the safety parameters for the analog input in the safety mat operation mode of the EK1960. This must be added to the logic and input value to determine the total PFH value.
Safety mat input parameters Value
PFH PFD MTTF DC
avg
D
G
D
8.84E-10
7.5E-05
high
medium Performance Level PLd Category 2 SIL 2
Logic safety parameters
The following table contains the safety parameters for the logic module of the EK1960. This must be added to the input and output value to determine the total PFH value. The Safety-over-EtherCAT communication is included in the logic part.
Product description
Logic parameters Value
PFH PFD MTTF DC
avg
D
G
D
5.18E-09
4.32E-05
high
high Performance Level PL e Category 4 SIL 3
Output safety parameters
The following table contains the safety parameters for the digital output of the EK1960. This must be added to the input and logic value to determine the total PFH value.
Digital output parameters Value
PFH PFD MTTF DC
avg
D
G
D
1.5E-10
2.62E-07
high
high Performance Level PL e Category 4 SIL 3
Examples of safety loops
Characteristic numbers Sample 1 Sample 2 Sample 3 Sample 4
Safety mat input PLd, Cat. 2 8.48E-10 8.48E-10 8.48E-10 8.48E-10 Digital input PLe, Cat. 4 6.4E-11 6.4E-11 Logic PLe, Cat. 4 5.18E-09 5.18E-09 5.18E-09 5.18E-09 5.18E-09 Digital output PLe, Cat. 4 1.5E-10 1.5E-10 1.5E-10 Relay output
PLe, Cat. 4 1.46E-09 1.46E-09
(Cat. 4) Relay output
PLd, Cat. 2 7.25E-10 7.25E-10
(Cat. 2)
Overall result
PFHD/ Performance
6.18E-09 PLd, Cat.2
5.39E-09 PLe, Cat.4
7.49E-09 PLd, Cat.2
6.75E-09 PLd, Cat.2
Level / Category

3.8 Error response times

The error response times depend, among other things, on the logic program used and the settings of the MultiplierDiagTestPulse and ModuloDiagTestPulse parameters.
An error reaction for the tests of the I/O signals is realized by a weighted counter, therefore the switch-off does not occur immediately at the first error of the diagnostic tests.
The maximum error reaction time results from the duration of the longest lasting test, this is the RAM test and this is several hours.
EK196026 Version: 1.3.1
Product description

3.9 Characteristic curve of the inputs

The characteristic curve of the inputs of the EK1960 is similar to type 3 according to EN 61131-2.
Fig.6: EK1960 input characteristic curve

3.10 Test pulses for the outputs

The output signals of each module of the EK1960 can be determined via the parameter Diag TestPulse Active. The test pulses generated have a length of 400 µs, which is multiplied by the factor MultiplierDiagTestPulse. This factor should be set to at least 2 for outputs with no load or only a small load,
so that a test pulse length of 800 µs results. The frequency of the test pulses results from the processing of the input and output modules and the cycle time of the internal logic. For example, if the logic has a cycle time of 2 ms and a ModuloDiagTestpulse of 0, a typical time b results in accordance with the following calculation.
For each output module the resulting time is:
module time = (4 cycles feedback test + (4 cycles diagnostic test *(ModuloDiagTestPulse + 1))) *internal cycle time*1.25* 4 outputs = (4 + (4 * 1)) * 2ms * 1.25 * 4 = 80ms
For the relay module the resulting time is:
Relay module time = 100 * internal cycle time * 1.25
The input modules each require one cycle. This results in a total time b of:
b=6 x module time + 1x relay module time + 10 x internal cycle timex1.25 (for the input modules)
Inserting the values, this produces:
b= (6 * 80ms) + (100 * 2ms * 1.25) + (10 * 2ms * 1.25) = 480ms + 250ms + 25ms = 755ms
The test pulse sequence is shown in the following table, where the time b typically elapses between a channel test and a module switch test. The tests start over once they have been performed for all four channels.
If the parameter Diag TestPulse for Inputs active is set in addition, all outputs of the module are switched on and the test pulses shown here are similarly applied to the individual output channels. These signals can then be used as clocked signals for the safe inputs. The module switch test is not performed in this operation mode; instead, the four channels are tested directly in succession, leading to the time interval b between the tests of the individual channels.
Product description
Test Time until next test
Channel 1 (only channel 1 is tested) b Module switch (all four channels are tested) b Channel 2 (only channel 2 is tested) b Module switch (all four channels are tested) b Channel 3 (only channel 3 is tested) b Module switch (all four channels are tested) b Channel 4 (only channel 4 is tested) b Module switch (all four channels are tested) b (next test channel 1)
NOTE
Length of the test pulses
When setting the test pulses, make sure that the connected actuator is not switched due to the test pulse length. The output signal must be 0 V for at least 200 µs within a test pulse. This is independent of the setting of the parameter MultiplierDiagTestPulse.
Minimum load
The test pulse length of the outputs is set by default to 2 x 400 µs. This setting is suitable for typical actuators with and without a protective circuit. The test pulse length can typically be reduced to 400 µs with a resistive load and a current of at least 30 mA. Please observe the violation counter in the diagnostic history. If messages are displayed for the cor­responding output module, this means that the setting of the test pulse length is borderline and may need to be increased. For electronic contactors that tend towards a capacitive behavior, it may be necessary to set the pa­rameter MultiplierDiagTestPulse to 3 or higher.
EK196028 Version: 1.3.1
Product description

3.11 Load characteristic curve – inductive load

If an external freewheeling diode is not used for inductive loads, the permissible maximum load can be taken from the following characteristic curve.
Fig.7: Characteristic curve - inductive load
Product description

3.12 Block diagram of the EK1960

The following block diagram shows the basic structure of the EK1960. The sub-modules shown exist several times according to the information on the sub-modules.
Fig.8: Block diagram EK1960
EK196030 Version: 1.3.1
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