BECKHOFF KL6904 User Manual

Operating instructions for

KL6904

TwinSAFE logic terminal with 4 fail-safe outputs

Version: 2.1.1
Date: 2015-11-03

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 K-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 KL1904, KL2904 – Bus Terminals with 4 fail-safe inputs or outputs 11

2.2.4 KL6904 TwinSAFE logic terminal with 4 fail-safe outputs 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

KL6904 1

Table of contents

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

4.1.4 Electrical installation 18

4.1.5 Tested devices 22

4.2 Configuration of the KL6904 in the TwinCAT System Manager 23

4.2.1 Configuration requirements 23

4.2.2 Inserting a Beckhoff Bus Coupler 23

4.2.3 Inserting a Beckhoff Bus Terminal 23

4.2.4 Inserting a KL6904 23

4.2.5 Address settings on the TwinSAFE terminals 25

4.2.6 Entering the TwinSAFE addresses in the System Manager 26

4.2.7 Creating a TwinSAFE group 27

4.2.8 Append a function block 30

4.2.9 KL6904 user and version administration 36

4.2.10 Loading the project into the KL6904 37

4.2.11 Communication between TwinCAT controllers 39

4.3 Diagnostics 43

4.3.1 Diagnostic LEDs 43

4.4 Maintenance 46

4.4.1 Cleaning 46

4.5 Service life 46

4.6 Decommissioning 47

4.6.1 Disposal 47

5 Appendix 48

5.1 Beckhoff Support and Service 48

5.1.1 Beckhoff branches and partner companies Beckhoff Support 48

5.1.2 Beckhoff company headquarters 48

5.2 Certificates 49

2

KL6904

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.

KL6904 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 (see chapter

Cleaning).

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

• the personnel is instructed regularly about relevant occupational safety and environmental

protection aspects, and is familiar with the operating instructions and in particular the safety
instructions contained herein.

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

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

4

KL6904

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

Attention

Note

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
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.

KL6904 5

Foreword

1.2.5 Documentation issue status

Version Comment

2.1.1

• Certificate updated

2.1.0

2.0.1

2.0.0

1.1.4

1.1.3

1.1.2

1.1.1

1.1.0

• Company address amended

• Document origin added

• Version history added

• EN954 example removed

• Safety parameters extended

• Reference to EN 60068-2-29 removed

• Description of the configuration in the TwinCAT System Manager added

• Certificates added

• Note on test pulses of the outputs added

• Tested devices extended

• Diagrams corrected

• Flash codes corrected

• Pin assignment corrected

• Technical data updated

• LED and graphics updated

• Technical data extended

• Editorial amendments

1.0.3

• Description of LEDs and blink codes updated

• TwinSAFE description updated

1.0.2

1.0.1

1.0.0

• Note relating to qualified software tool amended

• LoP list incorporated

• First publication

6

KL6904

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.

Since a wide range of different communication standards are established in industrial automation,
Beckhoff offers Bus Couplers for all common bus systems (e.g. BK3120 for PROFIBUS, BK9000 for
Ethernet, etc.).

KL6904 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) 47 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

KL6904

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 depending on fieldbus
Power contacts up to 3 blade/spring contacts
Current load 10 A
Rated voltage depends on Bus Terminal type

2.1.3 K-bus

The K-Bus is the data path within a terminal strip. The K-Bus is led through from the Bus Coupler through
all the terminals via six contacts on the terminals' side walls. The end terminal terminates the K-Bus.

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.

KL6904 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 KLx9xx series Bus Terminals only include three basic functionalities: digital KL19xx inputs,
digital KL29xx outputs and a KL6904 link unit. 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 KL6904. 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

• Logic link of the I/Os in the KL6904 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

• Freely selectable fieldbus connection with the KL6904 TwinSAFE logic terminal

KL6904 TwinSAFE logic Bus Terminal

• 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 1023 TwinSAFE devices

• TwinSAFE logic terminal can establish up to 15 connections (TwinSAFE connections).

• Several TwinSAFE logic terminals are cascadable in a network

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

• Safe outputs integrated

• Suitable for applications up to SIL 3 according to IEC 61508:2010

10

KL6904

System description

TwinSAFE digital input (KL1904) and output terminal (KL2904)

• All current safety sensors can be connected

• Operation with a TwinSAFE logic terminal

• KL1904 with 4 fail-safe inputs for sensors (24 VDC) with floating contacts

• KL2904 with four safe channels for actuators (24 VDC, 0.5 A per channel)

• conforming to IEC 61508:2010 SIL 3

2.2.3 KL1904, KL2904 – Bus Terminals with 4 fail-safe inputs or outputs

The KL1904 and KL2904 Bus Terminals enable connection of common safety sensors and actuators.
They are operated with the KL6904 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 KL6904. The user configures the KL6904 terminal according to
the safety requirements of his application.

2.2.4 KL6904 TwinSAFE logic terminal with 4 fail-safe outputs

The KL6904 TwinSAFE logic terminal is a digital output terminal with four fail-safe outputs with 0.5 A,
24 VDC. The KL6904 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.

KL6904 11

Product description

3 Product description

3.1 General description

KL6904 TwinSAFE logic terminal with four fail-safe outputs

The KL6904 is a safe small controller with digital outputs for connecting actuators (contactors, relays,
etc.) with a maximum current 0.5 A (24 VDC). The Bus Terminal has 4 fail-safe outputs.

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 Bus Terminal has the standard design of a Beckhoff Bus Terminal.

12

KL6904

Product description

3.2 Intended use

Caution - Risk of injury!

WARNING

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

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 (KL1904) 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 (KL2904, KL6904) such as
contactors, protective door switches with tumbler, signal lamps, servo drives etc.

Test pulses

Note

When selecting actuators please ensure that the KL6904 test pulses do not
lead to actuator switching or diagnostic message from the KL6904.
The test pulses of the KL6904 terminal outputs are not configurable and cannot
be switched off.

The following modules were developed for these tasks:

• The KL1904 terminal is an input module with digital inputs.

• The KL2904 terminal is an output module with digital outputs.

• The KL6904 terminal is a logic module with digital outputs.

These modules are suitable for operation with

• Beckhoff BKxxxx series Bus Couplers

• Beckhoff BXxxxx series Bus Terminal Controllers (with firmware version ≥ 1.20)

(Beckhoff BCxxxx series Bus Terminal Controllers are not supported!)

• Beckhoff CXxxxx series Embedded PCs with K-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.

KL6904 13

Product description

3.3 Technical data

Product designation KL6904

Number of inputs 0
Number of outputs 4
Status display 4 (one green LED per output)
Error reaction time ≤ watchdog times
Output current per channel max. 500 mA, min. 20 mA
Actuators

Cable length between
actuator and terminal

(unshielded) max. 100 m

(shielded) max. 100 m
Wire cross section min. 0.75 mm2
Input process image 192 byte max.
Output process image 192 byte max.
KL6904 supply voltage 24 VDC (-15%/+20%)
Current consumption from K-bus max. 250 mA
Power dissipation of the terminal typically 2 W
Electrical isolation (between the channels) no
Electrical isolation (between the channels and the

K-Bus)
Insulation voltage (between the channels and the

K-Bus, under common operating conditions)
Dimensions (W x H x D) 24 mm x 100 mm x 68 mm
Weight approx. 100 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 horizontal
Approvals CE, TÜV SÜD

When selecting actuators please ensure that the
output test pulses do not lead to actuator switching.

yes

insulation tested with 500 VDC

-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

14

KL6904

Product description

3.4 Safety parameters

Key figures KL6904

Lifetime [a] 20
Prooftest Intervall [a] not required 1)
PFH 1.73E-09
%SIL3 1.7%
PFD 1.42E-04
%SIL3 14.2%
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 KL6904 Bus 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 KL6904 Bus Terminal.

3.5 Dimensions

Width: 24 mm (side-by-side installation)
Height: 100 mm
Depth: 68 mm

KL6904 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

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

4.1 Installation

4.1.1 Safety instructions

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

KL6904

Operation

4.1.3 Mechanical installation

Serious risk of injury!

DANGER

Bring the bus system into a safe, de-energized state before starting installation,
disassembly or wiring of the Bus Terminals!

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 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.

KL6904 17

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 realized by
joining the components:

• The six spring contacts of the K-Bus deal with the transfer of the data and the supply of the Bus
Terminal electronics.

Note the maximum K-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 K-Bus!
Use the KL9400 Power Supply Terminal if the current consumption of your
terminals exceeds the maximum current that your Bus Coupler can feed to the
K-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 (KL91xx, KL92xx) interrupt the power contacts and thus
represent the start of a new supply rail.

18

KL6904

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 nominal 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!

KL6904 19

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 mm

2

20

KL6904

Operation

KL6904 pin assignment

Terminal

Output Signal

point

1 - not used, no function
2 positive power contact
3 - negative power contact
4 not used, no function
5 - not used, no function
6 positive power contact
7 - negative power contact
8 not used, no function
1’ 1 Output 1+
2’ Output 1­3’ 3 Output 3+
4’ Output 3­5’ 2 Output 2+
6’ Output 2­7’ 4 Output 4+
8’ Output 4-

Test pulses

Note

When selecting actuators please ensure that the KL2904 test pulses do not lead to
actuator switching or diagnostic message from the KL2904.
The test pulses of the KL6904 terminal outputs are not configurable and cannot be
switched off.

KL6904 21

Operation

4.1.5 Tested devices

The following list contains devices that were tested the together with the KL2904 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
Beckhoff KL2964 Three-channel contact extension with feedback

Siemens

Telemecanique LP1K09 Contactor
Dold

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

LG5929.54/100 Extension module with floating contacts

Recommended protective circuits

Note

We recommend R/C or diode-based protective circuits for these devices.
Varistor-based protective circuits should not be used.

22

KL6904

Operation

4.2 Configuration of the KL6904 in the TwinCAT System
Manager

Do not change the register values!

CAUTION

Do not change the register values for the TwinSAFE terminals. Changes to the register
values (e.g. with the KS2000 configuration software or via register communication) sets
the terminal permanently in the Fail-Stop state!

4.2.1 Configuration requirements

Version 2.10 build 1302 or higher of the TwinCAT automation software is required for configuring the
KL6904. The current version is available for download from the Beckhoff website at www.beckhoff.de.
In addition, the TwinSAFE Verifier must be installed. This is available on the Beckhoff Products &
Solutions CD. The current installation can also be obtained from Beckhoff Support, if required.

Once the TwinSAFE Verifier was installed successfully, the TwinSAFE Verifier tab is available in the
TwinCAT System Manager (further information can be found in section Loading the project into the
KL6904).

4.2.2 Inserting a Beckhoff Bus Coupler

See TwinCAT automation software documentation.

4.2.3 Inserting a Beckhoff Bus Terminal

See TwinCAT automation software documentation.

4.2.4 Inserting a KL6904

A KL6904 is inserted in the same way as any other Beckhoff Bus Terminal. In the list open Safety
Terminals (KLx9xx) and select the KL6904. The KL6904 can be selected with 7 or 15 TwinSAFE

connections.

KL6904 23

Operation

Size of the process image

Note

The process image should not be unnecessarily large.

If a KL6904 with 15 TwinSAFE connections is inserted, the KL6904 must be configured accordingly, since
the KL6904 is delivered with 7 configured connections. The KL6904 can be configured with the KS2000
configuration software from Beckhoff (firmware version 14 or higher).

After the changeover to the new process image the KL6904 must be de-energized and switched on again
in order to activate the change.

24

KL6904

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!

KL6904 25

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).

26

KL6904

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
KL6904. 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 KL6904 in the tree structure and
selecting Append TwinSAFE Group in the dialog box (see diagram).

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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.

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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:

FALSE:

TRUE:

FALSE:

At least one TwinSAFE connection of TwinSAFE group
has an error

All TwinSAFE connections of the TwinSAFE group have
no errors

At least one locally assigned output of the TwinSAFE
group has an error

All of the locally assigned outputs of the TwinSAFE group
have no errors

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Operation

4.2.8 Append a function block

The KL6904 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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Appended Emergency Stop block

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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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The inputs can now be linked.

Select the variable type:

KL6904 33

Operation

Clicking on the New button opens the following dialog:

All available channels are displayed as selected.
The required channel is selected and highlighted in blue with the mouse. The selection is confirmed via

the OK button.

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KL6904

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.

KL6904 35

Operation

4.2.9 KL6904 user and version administration

The KL6904 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 KL6904 (which cannot be
deleted) that indicates who activated what version of a project on the KL6904, and when.

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Operation

4.2.10 Loading the project into the KL6904

The project is loaded into the KL6904 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 KL6904!

Case-sensitive

Pay attention to upper/lower case characters for the user name and password.
User name and password are case-sensitive!

KL6904 37

Operation

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 KL6904.

4.2.10.1 KL6904 project design limits

TwinSAFE connections
TwinSAFE blocks
TwinSAFE groups
Standard PLC inputs
Standard PLC outputs

TwinSAFE connection

Note

Only one TwinSAFE connection between two TwinSAFE terminals is possible.

max. 7 or 15 (see Inserting a KL6904)
48 max.
8 max.
max. 24 bit
max. 24 bit

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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 KL6904 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.

The variables of type MASTER_MESSAGE and SLAVE_MESSAGE are now displayed, and both (In/Out)
have to be selected.

The selection is confirmed via the OK button.

KL6904 39

Operation

A new connection will appear in the list of TwinSAFE connections.
The connection has to be set on the associated tab.
One side must be a TwinSAFE master, the other one a TwinSAFE slave.
The F address of the partner device must also be set. Please not the DIP switch on the left-hand side of

the KL6904.

If several connections are to be established, a unique ID must be set for each Publisher variable.

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Operation

This ID must also be set on the partner device, i.e. the Subscriber.

KL6904 41

Operation

The network variables can now be used in the project. The inputs are shown under TwinSAFE Input, the
outputs under TwinSAFE Output.

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4.3 Diagnostics

4.3.1 Diagnostic LEDs

4.3.1.1 Diag 1 (green)

The Diag 1 LED indicates the state of the TwinSAFE interface.

Flashing Code Meaning

LED illuminated continuously normal operation:

TwinSAFE communication OK

rapid flickering, alternating with 1 flash pulse Communication error: at least one connection is

not in Run state.
rapid flickering, alternating with 2 flash pulses Error in the function block
rapid flickering, alternating with 3 flash pulses Error in the function block and

communication error: at least one connection is

not in Run state.

These errors can be rest through a falling edge at the ERR_ACK input of the TwinSAFE group.

KL6904 43

Operation

4.3.1.2 Diag 2 (red)

The Diag 2 LED indicates the state of the digital outputs.

Flashing Code Meaning

rapid flickering, alternating with 1 flash pulse Output 1: Open load or

current below minimum value of 20 mA or
current above maximum value of 500 mA

rapid flickering, alternating with 2 flash pulses Output 2: Open load or

current below minimum value of 20 mA or
current above maximum value of 500 mA

rapid flickering, alternating with 3 flash pulses Output 3: Open load or

current below minimum value of 20 mA or
current above maximum value of 500 mA

rapid flickering, alternating with 4 flash pulses Output 4: Open load or

current below minimum value of 20 mA or

current above maximum value of 500 mA
rapid flickering, alternating with 5 flash pulses Field potential too low
rapid flickering, alternating with 6 flash pulses Field potential too high
rapid flickering, alternating with 7 flash pulses Terminal temperature too low
rapid flickering, alternating with 8 flash pulses Terminal temperature too high
rapid flickering, alternating with 9 flash pulses Temperature difference error
rapid flickering, alternating with 10 flash pulses error in output circuit through Open Load,

external supply or cross-circuit

These errors can only be reset by switching the power supply for the TwinSAFE terminal off and back on
again.

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4.3.1.3 Diag 3 (red) and Diag 4 (red)

The Diag 3 and Diag 4 LEDs indicate internal terminal errors.

Returning the terminal

Note

These errors lead to shutdown of the terminal. The terminal must be checked by
Beckhoff Automation GmbH & Co. KG.

Diag 3 LED (red) Diag 4 LED (red) Source of error

lit flashing µC1
lit off µC2

In the event of a fault the Diag 4 LED indicates the type of error through flashing codes. The flashing
codes are structured as follows:

Flashing sequence Meaning

Rapid flickering Start of flashing code
First slow sequence Error code
Second slow sequence Error code argument

Start Error code Error code argument
Count the number of flash pulses after the rapid flickering sequence

• during the first slow sequence in order to ascertain the error code

• during the second slow sequence in order to ascertain the error argument

The flashing code is repeated after the second slow sequence, followed by rapid flickering.

KL6904 45

Operation

4.4 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 Global Fault state.

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

4.4.1 Cleaning

Protect the TwinSAFE terminals from unacceptable soling during operation and storage!
If the TwinSAFE terminals was subjected to unacceptable soiling it may no longer be operated!

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!

4.5 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.
The TwinSAFE terminals bear a date code, which is composed as follows:

Date code: CW YY SW HW

Legend:
CW: Calendar week of manufacture
YY: Year of manufacture
SW: Software version
HW: Hardware version

In addition the TwinSAFE terminals bear a unique serial number.

Example: Date code 17 11 05 00
Calendar week: 17
Year: 2011
Software version: 05
Hardware version: 00

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4.6 Decommissioning

Serious risk of injury!

DANGER

Bring the bus system into a safe, de-energized state before starting disassembly of the
Bus Terminals!

4.6.1 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.

KL6904 47

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: [e-mail]
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: [e-mail]

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: [e-mail]

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KL6904

Appendix

5.2 Certificates

KL6904 49

Appendix

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KL6904