BECKHOFF EL6930 User Manual

Operating instructions for

EL6930

TwinSAFE Logic Terminal with PROFIsafe gateway

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 EL6930 - TwinSAFE logic terminal with PROFIsafe gateway 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 15

4 Operation 16

4.1 Installation 16

4.1.1 Safety instructions 16

4.1.2 Transport / storage 16

4.1.3 Mechanical installation 17

EL6930 1

Table of contents

4.1.4 Electrical installation 19

4.1.5 Tested EL2904 devices 23

4.1.6 Tested EL1904 devices 23

4.2 Configuration of the EL6930 in the TwinCAT System Manager 24

4.2.1 Configuration requirements 24

4.2.2 Inserting a Beckhoff Bus Coupler 24

4.2.3 Inserting a Beckhoff Bus Terminal 25

4.2.4 Inserting an EL6930 25

4.2.5 Address settings on the TwinSAFE terminals 26

4.2.6 Entering the TwinSAFE addresses in the System Manager 27

4.2.7 Creating a TwinSAFE group 28

4.2.8 Append a function block 31

4.2.9 EL6930 user and version administration 37

4.2.10 Loading the project into the EL6930 38

4.2.11 Communication between TwinCAT controllers 40
Creating the PROFIsafe slave connection 44

4.3 Commissioning on Siemens F-CPU 47

4.3.1 Requirement 47

4.3.2 Installing the EL6930 in Step7 47

4.3.3 Configuration of the hardware 48

4.4 Diagnostics 51

4.4.1 Diagnostic LEDs 51

4.4.2 Diagnostic object 52

4.4.3 Status LEDs 53

4.5 Maintenance 54

4.5.1 Cleaning 54

4.6 Service life 54

4.6.1 Decommissioning 54

4.6.2 Disposal 54

5 Appendix 55

5.1 Beckhoff Support and Service 55

5.1.1 Beckhoff branches and partner companies Beckhoff Support 55

5.1.2 Beckhoff company headquarters 55

5.2 Certificates 56

2

EL6930

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.

EL6930 3

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.

• 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.

4

EL6930

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

WARNING

CAUTION

Failure to follow the safety instructions associated with this symbol directly endangers

the life and health of persons.

Caution - Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life

and health of persons.

Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries

to persons.

Damage to the environment or devices

Attention

Note

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.

1.2.4 Origin of the document

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

EL6930 5

Foreword

1.2.5 Documentation issue status

Version Comment

1.1.1

• Certificate updated

1.1.0

1.0.2

1.0.1

1.0.0

• Company address amended

• Documentation versions added

• References to EN954 removed

• Document origin added

• Description of PROFIsafe connection expanded

• Reference to EN 60068-2-29 removed

• First released version

6

EL6930

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).

EL6930 7

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 technology Bus Coupler

Wiring cage Clamp® spring-loaded system
Connection cross-section 0.08 mm2 ... 2.5 mm2, stranded wire, solid wire
Fieldbus connection depending on fieldbus
Power contacts 3 spring contacts
Current load 10 A
Rated voltage 24 VDC

8

EL6930

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.

EL6930 9

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 EL6930. 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 EL6930. 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 EL6930 TwinSAFE logic terminal

• Safety-relevant networking of machines via bus systems

TwinSAFE protocol (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 EL6930 TwinSAFE logic terminal

TwinSAFE logic Bus Terminal EL6930

• 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 127 connections (TwinSAFE connections) and a

PROFIsafe slave connection to a PROFIsafe master controller.

• 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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EL6930

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 EL6930 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 EL6930. The user configures the EL6930 terminal according to
the safety requirements of his application.

2.2.4 EL6930 - TwinSAFE logic terminal with PROFIsafe gateway

The TwinSAFE logic terminal is the link unit between the TwinSAFE input and output terminals and a
gateway to a PROFIsafe master controller. The EL6930 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.

EL6930 11

Product description

3 Product description

3.1 General description

EL6930 - TwinSAFE logic terminal / PROFIsafe gateway

The TwinSAFE logic terminal is the link unit between the TwinSAFE input and output terminals.
The EL6930 meets the requirements of IEC 61508:2010 SIL 3, DIN EN ISO 13849-1:2006 (Cat 4, PL e),

NRTL, UL508, UL1998 and UL991.
The TwinSAFE terminal has the typical design of an EtherCAT terminal.

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EL6930

Product description

3.2 Intended use

Caution - Risk of injury!

WARNING

The TwinSAFE terminals expand the application range of Beckhoff Bus Terminal system with functions
that enable them to be used for machine safety applications. The TwinSAFE terminals are designed for
machine safety functions and directly associated industrial automation tasks. They are therefore only
approved for applications with a defined fail-safe state. This safe state is the wattless state. Fail-safety
according to the relevant standards is required.

The TwinSAFE terminals enable connection of:

• 24 VDC sensors (EL1904) such as
emergency stop push buttons, pull cord switches, position switches, two-hand switches, safety
mats, light curtains, light barriers, laser scanners etc.

• 24 VDC actuators (EL2904) such as
contactors, protective door switches with tumbler, signal lamps, servo drives etc.

TwinSAFE terminals may only be used for the purposes described below!

Test pulses

Note

When selecting actuators please ensure that the EL2904 test pulses do not
lead to actuator switching or diagnostic message from the EL2904.

The following modules were developed for these tasks:

• The EL1904 terminal is an input module with digital inputs.

• The EL2904 terminal is an output module with digital outputs.

• The EL6930 terminal is a logic module.

These modules are suitable for operation with

• Beckhoff EKxxxx series Bus Couplers

• Beckhoff CXxxxx series Embedded PCs with E-bus connection

Follow the machinery directive

CAUTION

The TwinSAFE terminals may only be used in machines according to the Machinery
Directive.

Ensure traceability

CAUTION

The buyer has to ensure the traceability of the device via the serial number.

EL6930 13

Product description

3.3 Technical data

Product designation EL6930

Number of inputs 0
Number of outputs 0
Status display 4 diagnostic LEDs
Minimum cycle time approx. 500 µs
Error reaction time ≤ watchdog times
Watchdog time min. 1 ms, max. 60,000 ms
Input process image

Output process image

EL6930 supply voltage 24 VDC (-15%/+20%)
Current consumption from the E-bus approx. 188 mA
Power dissipation of the terminal typically 1 W
Dimensions (W x H x D) 12 mm x 100 mm x 68 mm
Weight approx. 50 g
Permissible ambient temperature (operation) 0 ℃ to +55 ℃
Permissible ambient temperature

(transport/storage)
Permissible air humidity 5 % to 95 %, non-condensing
Permissible air pressure

(operation/storage/transport)
Climate category according to EN 60721-3-3 3K3
Permissible level of contamination

Impermissible operating conditions

Vibration / shock resistance according to EN 60068-2-6 / EN 60068-2-27
EMC immunity/emission according to EN 61000-6-2 / EN 61000-6-4
Shocks 15 g with pulse duration 11 ms in all three axes
Protection class IP20
Permitted operating environment

Permissible installation position
Approvals CE, TÜV SÜD

Dynamic according to the TwinSAFE configuration in
the TwinCAT System Manager

Dynamic according to the TwinSAFE configuration in
the TwinCAT System Manager

-25 ℃ to +70 ℃

750 hPa to 1100 hPa

level of contamination 2
(comply with the chapter Cleaning)

TwinSAFE terminals must not be used under the
following operating conditions:

• under the influence of ionizing radiation

• in corrosive environments

• in an environment that leads to

unacceptable soiling of the Bus Terminal

control cabinet or terminal box with minimum
protection class IP54 according to IEC 60529

see section Installation position

14

EL6930

Product description

3.4 Safety parameters

Key figures EL6930

Lifetime [a] 20
Prooftest Intervall [a] not required 1)
PFH 1.03E-09
%SIL3 1.03%
PFD 8.23E-05
%SIL3 8.23%
MTTFd [a] >100
DC >99%
Performance level PL e
Category 4
HFT 1
Element classification* Type A
*) Classification according to IEC 61508-2:2010 (see chapters 7.4.4.1.2 and 7.4.4.1.3)

The EL6930 EtherCAT Terminal can be used for safety-related applications within the meaning of
IEC 61508:2010 up to SIL3 and EN ISO 13849-1 up to PL e (Cat4).

1)

Special proof tests are not required during the entire service life of the EL6930 EtherCAT terminal.

3.5 Dimensions

Width: 12 mm (side-by-side installation)
Height: 100 mm
Depth: 68 mm

EL6930 15

Operation

4 Operation

Please ensure that the TwinSAFE terminals are only transported, stored and operated under the specified
conditions (see technical data)!

Caution - Risk of injury!

WARNING

4.1 Installation

4.1.1 Safety instructions

The TwinSAFE terminals must not be used under the following operating conditions:

• under the influence of ionizing radiation

• in corrosive environments

• in an environment that leads to unacceptable soiling of the Bus Terminal

Before installing and commissioning the TwinSAFE terminals please read the safety notes in the foreword
of this documentation.

4.1.2 Transport / storage

Use the original packaging for transporting or storing the digital TwinSAFE terminals.

Note the specified environmental conditions

CAUTION

Please ensure that the digital TwinSAFE terminals are only transported and stored
under the specified environmental conditions (see technical data).

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EL6930