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).
10
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.
12
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).
16
EL6930
Operation
4.1.3 Mechanical installation
Serious risk of injury!
DANGER
4.1.3.1 Control cabinet
The TwinSAFE terminals must be installed in a control cabinet or terminal box with IP54 protection class
according to IEC 60529 as a minimum.
4.1.3.2 Installation position
For the prescribed installation position the mounting rail is installed horizontally and the mating surfaces
of the EL/KL terminals point toward the front (see illustration below). The terminals are ventilated from
below, which enables optimum cooling of the electronics through convection. "From below" is relative to
the acceleration of gravity.
Bring the bus system into a safe, de-energized state before starting installation,
disassembly or wiring of the Bus Terminals!
EL6930 17
Operation
4.1.3.3 Mounting rail installation
Installation
The Bus Couplers and Bus Terminals are attached to commercially available 35 mm mounting rails
(according to EN 60715) by applying slight pressure:
1. First attach the Fieldbus Coupler to the mounting rail.
2. The Bus Terminals are now attached on the right-hand side of the fieldbus Coupler. Join the
components with slot and key and push the terminals against the mounting rail, until the lock
clicks onto the mounting rail.
If the terminals are clipped onto the mounting rail first and then pushed together without slot
and key, the connection will not be operational! When correctly assembled, no significant gap
should be visible between the housings.
3. During the installation of the Bus Terminals, the locking mechanism of the terminals must not
come into conflict with the fixing bolts of the mounting rail.
18
EL6930
Operation
Removal
1. Carefully pull the orange-colored lugs approximately 1 cm out of the disassembled terminal, until
they protrude loosely. The lock with the mounting rail is now released for this terminal, and the
terminal can be pulled from the mounting rail without excessive force.
2. Grasp the released terminal with thumb and index finger simultaneous at the upper and lower
grooved housing surfaces and pull the terminal away from the mounting rail.
4.1.4 Electrical installation
4.1.4.1 Connections within a Bus Terminal block
The electric connections between the Bus Coupler and the Bus Terminals are automatically realised by
joining the components:
• The six spring contacts of the E-bus deal with the transfer of the data and the supply of the Bus
Terminal electronics.
Note the maximum E-bus current!
Note
• The power contacts deal with the supply for the field electronics and thus represent a supply rail
within the Bus Terminal block. The power contacts are supplied via terminals on the Bus Coupler.
Note
Observe the maximum current that your Bus Coupler can supply to the E-bus!
Use the EL9400 Power Supply Terminal if the current consumption of your
terminals exceeds the maximum current that your Bus Coupler can feed to the
E-bus supply.
Note the pin assignment of the power contacts!
During the design of a Bus Terminal block, the pin assignment of the individual
Bus Terminals must be taken account of, since some types (e.g. analog Bus
Terminals or digital 4-channel Bus Terminals) do not or not fully loop through the
power contacts.
Power Feed Terminals (EL91xx, EL92xx) interrupt the power contacts and thus
represent the start of a new supply rail.
EL6930 19
Operation
PE power contact
The power contact labelled PE can be used as a protective earth. For safety reasons this contact mates
first when plugging together, and can ground short-circuit currents of up to 125 A.
Insulation tests
CAUTION
DANGER
Note that, for reasons of electromagnetic compatibility, the PE contacts are
capacitatively coupled to the mounting rail. This may lead to incorrect results during
insulation testing or to damage on the terminal (e.g. disruptive discharge to the PE line
during insulation testing of a consumer with a rated voltage of 230 V).
For insulation testing, disconnect the PE supply line at the Bus Coupler or the Power
Feed Terminal! In order to decouple further feed points for testing, these Power Feed
Terminals can be released and pulled at least 10 mm from the group of terminals.
Serious risk of injury!
The PE power contact must not be used for other potentials!
20
EL6930
Operation
4.1.4.2 Wiring
Up to eight connections enable the connection of solid or finely stranded cables to the Bus Terminals.
The terminals are implemented in spring force technology. Connect the cables as follows:
1. Open a spring-loaded terminal by slightly pushing with a screwdriver or a rod into the
square opening above the terminal.
2. The wire can now be inserted into the round terminal opening without any force.
3. The terminal closes automatically when the pressure is released, holding the wire safely
and permanently.
Wire cross section
Strip length
0.08... 2.5 mm
8 ...9 mm
2
EL6930 21
Operation
EL6930 pin assignment
Terminal
Output Signal
point
1 - not used, no function
2 not used, no function
3 - not used, no function
4 not used, no function
5 - not used, no function
6 not used, no function
7 - not used, no function
8 not used, no function
22
EL6930
Operation
4.1.5 Tested EL2904 devices
The following list contains devices that were tested together with the EL2904 TwinSAFE terminal. The
results only apply for the current device hardware version at the time of testing. The tests were carried out
in a laboratory environment. Modifications of these products cannot be considered here. If you are unsure
please test the hardware together with the TwinSAFE terminal.
Manufacturer Type Comment
Beckhoff AX5801 TwinSAFE Drive option card: safe restart lock
Beckhoff AX2000 Option AS safe restart lock
Siemens
Telemecanique LP1K09 Contactor
The tests were carried out as function tests only. The information provided in the respective manufacturer
documentation remains valid.
SIRIUS Serie S00
Contactor
3RT1016-1BB42
Recommended protective circuits
Note
We recommend R/C or diode-based protective circuits for these devices.
Varistor-based protective circuits should not be used.
4.1.6 Tested EL1904 devices
The following list contains devices that were tested together with the EL1904 TwinSAFE terminal. The
results only apply for the current device hardware version at the time of testing. The tests were carried out
in a laboratory environment. Modifications of these products cannot be considered here. If you are unsure
please test the hardware together with the TwinSAFE terminal.
Manufacturer Type Comment
SICK C4000
SICK
Wenglor
S3000 Safety laser scanner
SG2-14ISO45C1 Safety light grids
Leuze lumiflex ROBUST 42/43/44 Safety light barriers
Schmersal BNS250-11ZG Safety switch
ifm GM701S Inductive safety sensor
The tests were carried out as function tests only. The information provided in the respective manufacturer
documentation remains valid.
Safety light curtain
EL6930 23
Operation
4.2 Configuration of the EL6930 in the TwinCAT System
Manager
Do not change the register values!
CAUTION
Do not change any of the CoE objects in the TwinSAFE terminals. Any modifications
(e.g. via the System Manager) of the CoE objects would permanently set the terminals
to the Fail-Stop state.
4.2.1 Configuration requirements
Version 2.11 build 2208 or higher of the TwinCAT automation software is required for configuring the
EL6930. The current version is available for download from the Beckhoff website at www.beckhoff.de.
4.2.2 Inserting a Beckhoff Bus Coupler
See TwinCAT automation software documentation.
24
EL6930
Operation
4.2.3 Inserting a Beckhoff Bus Terminal
See TwinCAT automation software documentation.
4.2.4 Inserting an EL6930
An EL6930 is inserted in the same way as any other Beckhoff Bus Terminal. In the list open Safety
Terminals (ELx9xx) and select the EL6930.
Size of the process image
Note
The process image of the EL6930 is adjusted dynamically based on the TwinSAFE
configuration created in the TwinCAT System Manager.
EL6930 25
Operation
4.2.5 Address settings on the TwinSAFE terminals
The TwinSAFE address of the terminal is set via the 10-way DIP switch on the left-hand side of the
TwinSAFE Bus Terminal. TwinSAFE addresses between 1 and 1023 are available.
DIP switch Address
1 2 3 4 5 6 7 8 9 10
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 0
ON
OFF
ON ON
OFF OFF
ON
OFF
ON ON ON
OFF OFF OFF OFF OFF OFF OFF OFF OFF 1
ON
OFF OFF OFF OFF OFF OFF OFF OFF 2
OFF OFF OFF OFF OFF OFF OFF OFF 3
ON
OFF
ON
ON ON
OFF OFF OFF OFF OFF OFF OFF 4
OFF OFF OFF OFF OFF OFF OFF 5
OFF OFF OFF OFF OFF OFF OFF 6
OFF OFF OFF OFF OFF OFF OFF 7
... ... ... ... ... ... ... ... ... ... ...
ON ON ON ON ON ON ON ON ON ON
1023
Unique TwinSAFE address
WARNING
Each TwinSAFE address may only be used once within a network!
26
EL6930
Operation
4.2.6 Entering the TwinSAFE addresses in the System Manager
The TwinSAFE address set at the DIP switch must also be entered under the TwinSAFE Logic tab
(TwinSAFE address entry).
EL6930 27
Operation
4.2.7 Creating a TwinSAFE group
A TwinSAFE group is a group of TwinSAFE terminals (inputs and outputs) that are logically linked via a
EL6930. Any communication faults in the TwinSAFE connections of this group lead to the whole group
being switched off. Other TwinSAFE groups are not affected.
A TwinSAFE group is added by right-clicking on the associated EL6900/EL6930 in the tree structure and
selecting Append TwinSAFE group in the dialog box (see diagram).
28
EL6930
Operation
4.2.7.1 TwinSAFE group signals
TwinSAFE group inputs
Name Permitted type Description
RUN FB-Out
TRUE:
Standard-In
FALSE:
ERR Ack FB-Out
Standard-In
All pending errors in the assigned function blocks and in the
TwinSAFE connections are acknowledged by the FALSE->TRUE>FALSE signal sequence.
The function blocks assigned to the TwinSAFE group are
executed. When the input is not linked it is in the TRUE
state
All of the TwinSAFE group assigned function blocks are at
a STOP state and thus all associated outputs are in a safe
state.
EL6930 29
Operation
TwinSAFE group outputs
Name Permitted type Description
FB ERR TwinSAFE-Out
TRUE: At least one assigned function block has an error
FB-In
Standard-Out
FALSE: All assigned function blocks have no errors
COM ERR TwinSAFE-Out
FB-In
Standard-Out
OUT ERR TwinSAFE-Out
FB-In
Standard-Out
TRUE:
At least one TwinSAFE connection of TwinSAFE group
has an error
FALSE:
All TwinSAFE connections of the TwinSAFE group have
no errors
Always FALSE, since the EL6930 has no local outputs
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EL6930
Operation
4.2.8 Append a function block
The EL6900/EL6930 TwinSAFE logic terminal features the following blocks: Emergency Stop, Machine
Monitoring, AND, OR, Decoupler, Operation Mode, etc.
A function block is added by right-clicking on the associated TwinSAFE function block list in the tree
structure and selecting Append Function Block in the dialog box with the left mouse button (see diagram).
The required function block can then be selected from the following window.
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Operation
Appended Emergency Stop block
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EL6930
Operation
4.2.8.1 Activating and configuring the block inputs
The following parameters can be set:
Deactivated: The input is not used
Single-channel: The inputs are linked independent of each other
Two-channel: The inputs are monitored for equality or inequality, depending on the contact type
setting. A Discrepancy Time can be set for monitoring the two inputs for simultaneous
switching.
Make Contact: Contact type setting
Break Contact Contact type setting
The inputs are now activated.
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Operation
The inputs can now be linked.
Select the variable type:
34
EL6930
Operation
Clicking on the New button opens the following dialog:
All available channels are displayed as selected.
The desired channel is selected and marked with the mouse. The selection is confirmed via the OK
button.
EL6930 35
Operation
The name of the variables should now be entered in the Link Alias field.
Repeat the process for the other inputs. Inputs that are already in use are identified with an arrow.
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EL6930
Operation
4.2.9 EL6930 user and version administration
The EL6930 has a user administration function. The administrator can create further users and issue
associated passwords.
Clicking on the Version History button will bring up the version history for the EL6930 (which cannot be
deleted) that indicates who activated what version of a project on the EL6930, and when.
EL6930 37
Operation
4.2.10 Loading the project into the EL6930
The project is loaded into the EL6930 via the fieldbus.
Use only qualified tools
CAUTION
Click the Download button on the TwinSAFE Verifier tab for loading the project.
The user must enter
• his user name (default: Administrator),
• the terminal serial number (printed on the outside, e.g. 197535), and
• his password (default: TwinSAFE).
Note
Only use a qualified tool for loading, verifying and enabling the project on the EL6930!
Case-sensitive
Pay attention to upper/lower case characters for the user name and password.
User name and password are case-sensitive!
The project is then displayed in text mode, and the user has to confirm consistency between the
information displayed and the currently projected application by re-entering the password. The project is
then started on the EL6900/EL6930.
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EL6930
Operation
4.2.10.1 EL6930 project design limits
TwinSAFE connections
PROFIsafe connections
Supported hardware for EL6930
TwinSAFE connections
Safe data per connection
TwinSAFE blocks
TwinSAFE groups
Standard PLC inputs
Standard PLC outputs
TwinSAFE connection
max. 127 (with 1 or 2 bytes safe user data per connection)
max. 50 connections per TwinSAFE group
Only 16 connections of an EL6930 can be slave connections.
1 PROFIsafe slave connection (must always be the first connection
in the configuration)
EL1904 (all)
EL2904 (all)
EL2902 (all)
KL1904 (from 2008)
KL2904 (from 2008)
KL6904 as slave (from 2008)
AX5805 (all)
up to 14 bytes safe user data (correspondingly lower total number
of connections)
255 max.
32 max.
dynamic up to 255-bit
dynamic up to 255-bit
Note
Only one TwinSAFE connection between two TwinSAFE terminals is possible.
Between two EL6900/EL6930 logic terminals a connection can be set up that may
contain up to 14 bytes safe user data.
EL6930 39
Operation
4.2.11 Communication between TwinCAT controllers
The MASTER_MESSAGE and SLAVE_MESSAGE data types are used for communication between two
or more TwinCAT controllers via network variables.
Associated variables have to be created under Publisher and Subscriber on the communicating
controllers.
During TwinSAFE communication one side acts as the master, the other one as the slave.
This results in the following data types:
TwinSAFE Master Publisher MASTER_MESSAGE
TwinSAFE Master Subscriber SLAVE_MESSAGE
TwinSAFE Slave Publisher SLAVE_MESSAGE
TwinSAFE Slave Subscriber MASTER_MESSAGE
The link with the via TwinSAFE logic terminal EL6930 is established with the following dialog:
The connection created must now be made known to the TwinSAFE logic terminal. This is done by
marking the TwinSAFE connection list and pressing the right mouse button.
Create a new connection in the list of connections and create associated variables of the required type
40
EL6930
Operation
under Module1 (FSoE).
These newly-created variables are now linked with the network variables already created. This is carried
out for both the master and the slave message.
EL6930 41
Operation
The settings for the TwinSAFE connection can then be set, including FSoE address, FSoE watchdog and
the communication device type. In addition, the connection can be identified as FSoE master or FSoE
slaves, and the information to be mapped in the cyclic process image can be specified.
If several connections are to be established, a unique ID must be set for each Publisher variable.
This ID must also be set on the partner device, i.e. the Subscriber.
42
EL6930
Operation
The network variables can now be used in the project. The inputs are shown TwinSAFE Input, the outputs
under TwinSAFE Output.
EL6930 43
Operation
Creating the PROFIsafe slave connection
The EL6930 supports a PROFIsafe slave connection, which must always be created as the first
TwinSAFE connection. The procedure for this is as follows:
1. Append a TwinSAFE message structure to the TwinSAFE connection list of the first TwinSAFE
Group:
2. Insert the corresponding PROFIsafe message variable (VARTYPE_PROFISAFEMESSAGE_5 for
a 5-byte PROFIsafe message (1 byte safe data), VARTYPE_PROFISAFEMESSAGE_6 for a 6byte PROFIsafe message (2 bytes safe data), VARTYPE_PROFISAFEMESSAGE_8 for an 8byte PROFIsafe message (4 bytes safe data)) on the first TxPDO under module 1 of the EL6930:
44
EL6930
Operation
3. Link the variable with the appropriate variable of the PROFIsafe module:
4. Insert the corresponding PROFIsafe message variable on the first RxPDO under module 1 of the
EL6930:
EL6930 45
Operation
5. Link the variable with the appropriate variable of the PROFIsafe module:
6. Set the connection type PROFIsafe Slave on the Connection tab of the TwinSAFE connection
added in step 1:
46
EL6930
Operation
4.3 Commissioning on Siemens F-CPU
4.3.1 Requirement
The requirement for the commissioning of the EL6930 with a PROFIsafe connection is a safety controller
with PROFIBUS or PROFINET and with a certified PROFIsafe host. Furthermore the Simatic Step7
program with the extension S7 distributed Safety is needed for the configuration.
4.3.2 Installing the EL6930 in Step7
So that the EL6930 is selectable later in the device catalogue, the device description file for PROFIBUS
(GSD) or PROFINET (GSDML) must be installed first. This can be done in the Step7 program HW Config
as follows:
EL6930 47
Operation
4.3.3 Configuration of the hardware
First of all the head station must be selected from the device catalogue of the HW Config (CX8031 with
Profibus is used here as an example).
The EL6930 presents itself to this head station as a normal module and can be added in the usual way.
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EL6930
Operation
The F-parameters can be adjusted by double-clicking on the module.
4.3.3.1 F_Check_SeqNr
Valid only for PROFIsafe version 1. With this you can set whether or not the SeqNr is included in the CRC
calculation of the PROFIsafe telegram (default is No Check).
4.3.3.2 F_SIL
Specification of the SIL level; the EL6930 always has SIL3.
EL6930 49
Operation
4.3.3.3 F_CRC_Length
Length of the checksum in the PROFIsafe telegram; the EL6930 has a 2-byte checksum for PROFIsafe
version 1 and a 3-byte checksum for version 2. This value must be consistent with the parameter
F_PAR_Version.
4.3.3.4 F_PAR_Version
Indicates the version of the PROFIsafe connection. The EL6930 supports PROFIsafe versions 1 and 2.
This value must be consistent with the parameter F_CRC_Length.
4.3.3.5 F_Source_Add
Address of the PROFIsafe host; this is specified by the configuration program.
4.3.3.6 F_Dest_Add
Address of the PROFIsafe device; this is assigned by the user and must be unique in the entire safety
network.
4.3.3.7 F_WD_Time
This parameter sets the watchdog for the safety connection. The value must always be higher than the
cycle time of the fieldbus, since it can take several fieldbus cycles before a PROFIsafe telegram is
dispatched.
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EL6930
Operation
4.4 Diagnostics
4.4.1 Diagnostic LEDs
The LEDs Diag 1 to Diag 4 display diagnostic information for the EL6930.
4.4.1.1 Diag 1 LED (green)
The Diag 1 LED is currently always on when a project is loaded into the terminal.
Display Meaning
lit A project is stored in the terminal.
4.4.1.2 Diag 2 LED (red)
The Diag 2 LED indicates internal process variable errors (in preparation).
Display Meaning
in preparation
4.4.1.3 Diag 3 LED (red)
The Diag 3 LED provides further details for the Diag 4 LED (see below).
4.4.1.4 Diag 4 LED (red) if Diag 3 LED (red) is lit
If the Diag 3 LED is lit, the Diag 4 LED indicates internal terminal errors.
Diag 3 LED Diag 4 LED Source of error
lit flashing µC1
lit off µC2
Returning the terminal
Note
EL6930 51
These errors lead to the shutdown of the terminal (global fault). The terminal must be
checked by Beckhoff Automation GmbH & Co. KG.
Operation
4.4.1.5 Diag 4 LED (red) if Diag 3 LED (red) is not lit.
If the Diag 3 LED is not lit, the Diag 4 LED indicates the state of the TwinSAFE terminal.
Diag 3 LED Diag 4 LED: Flashing Code Meaning
off 1 flash pulse (uniform flashing) Function block error in one of the TwinSAFE
groups
off 2 flash pulses (2 pulses with longer
pause in between)
off 3 flash pulses (3 pulses with longer
pause in between)
Communication error in one of the TwinSAFE
groups
Function block and communication error in
one of the TwinSAFE groups
off Steadily lit Supply voltage or internal temperature of the
terminal outside the permissible range. The
diagnostic object FA00
provides you with
hex
more detailed information.
4.4.2 Diagnostic object
The CoE object FA00
displays further diagnostic information.
hex
Do not change CoE objects!
Do not change any of the CoE objects in the TwinSAFE terminals! Any modifications
CAUTION
(e.g. using the TwinCAT system manager) of the CoE objects would permanently set
the terminals to the Fail-Stop state.
Index FA00
: Diagnostic object
hex
Index Name Meaning Flags
FA00:0 Diag RO
FA00:03
Temper
ature
error
0005
0006
0007
Maximum temperature exceeded RO 0000
hex
Temperature fell below minimum
hex
hex
Temperature difference between the measuring
points exceeded
Supply
error
0101
0102
0103
0104
max. supply voltage µC1 exceeded
hex
max. supply voltage µC2 exceeded
hex
voltage fell below max. supply voltage µC1
hex
voltage fell below max. supply voltage µC2
hex
Default
value
hex
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EL6930
Operation
4.4.3 Status LEDs
The LEDs State 1 to State 4 indicate the current status of the EL6900.
State 1 State 2 State 3 State 4 Meaning
off off off lit
off off lit lit
lit lit lit lit
• No project present on the terminal
• Project present on the terminal
• EtherCAT status: Pre-Operational (Pre-OP)
• Project present on the terminal
• EtherCAT status: Operational (OP)
EL6930 53
Operation
4.5 Maintenance
The TwinSAFE terminals are maintenance-free!
Observe the specified environmental conditions!
WARNING
If the terminal is operated outside the permitted temperature range it will switch to the Global Fault state
(see section Diagnose).
4.5.1 Cleaning
Protect the TwinSAFE terminals from unacceptable soling during operation and storage!
If the TwinSAFE terminals were subjected to unacceptable soiling it may no longer be operated!
Please ensure that the TwinSAFE terminals are only stored and operated under the
specified conditions (see technical data).
Have soiled terminals checked!
WARNING
Cleaning of the TwinSAFE terminals by the user is not permitted!
Please send soiled terminals to the manufacturer for inspection and cleaning!
4.6 Service life
The TwinSAFE terminals are designed for a service life of 20 years.
Due to the high diagnostic coverage within the lifecycle no special proof tests are required.
4.6.1 Decommissioning
Serious risk of injury!
DANGER
4.6.2 Disposal
In order to dispose of the device, it must be removed and fully dismantled.
• Housing components (polycarbonate, polyamide (PA6.6)) are suitable for plastic recycling.
• Metal parts can be sent for metal recycling.
• Electronic parts such as disk drives and circuit boards must be disposed of in accordance with
national electronics scrap regulations.
Bring the bus system into a safe, de-energized state before starting disassembly of the
Bus Terminals!
54
EL6930
Appendix
5 Appendix
5.1 Beckhoff Support and Service
Beckhoff and their partners around the world offer comprehensive support and service, making available
fast and competent assistance with all questions related to Beckhoff products and system solutions.
5.1.1 Beckhoff branches and partner companies Beckhoff Support
Please contact your Beckhoff branch office or partner company for local support and service on Beckhoff
products!
The contact addresses for your country can be found in the list of Beckhoff branches and partner
companies: www.beckhoff.com. You will also find further documentation for Beckhoff components there.
5.1.2 Beckhoff company headquarters
Beckhoff Automation GmbH & Co.KG
Huelshorstweg 20
33415 Verl
Germany
Phone: + 49 (0) 5246/963-0
Fax: + 49 (0) 5246/963-198
E-mail: info@beckhoff.com
Web: www.beckhoff.com
Beckhoff Support
Support offers you comprehensive technical assistance, helping you not only with the application of
individual Beckhoff products, but also with other, wide-ranging services:
• world-wide support
• design, programming and commissioning of complex automation systems
• and extensive training program for Beckhoff system components
Hotline: + 49 (0) 5246/963-157
Fax: + 49 (0) 5246/963-9157
E-mail: support@beckhoff.com
Beckhoff Service
The Beckhoff Service Center supports you in all matters of after-sales service:
• on-site service
• repair service
• spare parts service
• hotline service
Hotline: + 49 (0) 5246/963-460
Fax: + 49 (0) 5246/963-479
E-mail: service@beckhoff.com
EL6930 55
Appendix
5.2 Certificates
56
EL6930
Appendix
EL6930 57
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