turck TBPN-L1-FDIO1-2IOL Safety Manual

Your Global Automation Partner

TBPN-L1-FDIO1-2IOL

Safety Block I/O Module

Safety manual - Translation

2 Hans Turck GmbH & Co. KG | T [phone] | F [phone] | [e-mail] | www.turck.com

Table of Content

1 About this document 5

2 Scope 5

3 Safety Integrity Level/Performance Level/Category 5

4 Product description 6

4.1 Intended use 6

4.1.1 Foreseeable misuse 6

4.2 Device overview 6

4.3 Type plate 7

4.4 Switches and connectors 7

4.5 Block diagram 7

5 Safety function 8

5.1 Safe status 8

5.2 Fatal Error 8

6 Safety planning 8

6.1 Prerequisites 8

6.2 Reaction time 8

6.3 Safety characteristic data 9

7 Operating instructions 9

7.1 General 9

7.2 Before operation 10

7.2.1 Mounting 10

7.2.2 Connection 11

7.2.3 Address assignment 12

7.2.4 Conguring 12

7.3 Operation 13

7.3.1 Indication elements 13

7.3.2 Output error behavior 14

7.3.3 Decommissioning 14

8 Appendix: Wiring diagram 14

8.1 Ethernet 14

8.2 Power supply 14

8.3 Safety inputs 14

8.4 Safety in-/outputs 15

8.5 DXP 15

8.6 IO-Link 15

9 Appendix: Connection examples 16

9.1 Inputs 16

9.2 Outputs 16

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10 Appendix: Designations and abbreviations 17

11 Appendix: Function tests 17

12 Appendix: Document history 17

13 Appendix: Technical data 18

14 Appendix: Declaration of Conformity 20

4

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1 About this document

This safety manual contains all information that is required by users to operate the device in
functional safety systems. Read this manual carefully before using the device.

This document addresses only functional safety according EN ISO 13849-1 and EN/IEC 61508.
Other issues are not considered.

All instructions must be followed in order to assure functional safety.

Always make sure that this is the latest version of the safety manual at www.turck.com.
TheGerman versionis considered the definitive document. Every care was taken in the produc­tion of the translations of this document. If there is any uncertainty in its interpretation, refer to
theGerman version of the safety manual or contact TURCK directly.

2 Scope

This safety manual is valid for the Turck PROFIsafe device TBPN-L1-FDIO1-2IOL.

3 Safety Integrity Level/Performance Level/Category

The devices are rated for applications up to:

SIL3 according to EN/IEC 61508 and EN/IEC 62061

■

Category 4/PLe according to EN ISO 13849-1

■

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5

Product description

4 Product description

The TBPN-L1-FDIO1-2IOL is a safety block I/O module for safety applications with PROFIsafe
over PROFINET.

The device provides two safety SIL3-inputs (FDI) to connect 2-channel mechanical safety
switches and electronic safety sensors (OSSD).
Two further SIL3-channels (FDX) can be freely used as inputs (FDI) or outputs (FDO). The safety
outputs serve for the safe shutdown of loads (resistive up to 2 A).
For non-safety functions, the device provides four universal in-/outputs (DXP) at C4 as well
as two IO-Link master channels (IOL) at C6 and C7 for connecting IO-Link sensors and IO-Link
hubs. Additionally, the IO-Link slots each provide one digital in-/output at pin 2.
The non-safety ports C4, C5 and C7 can be switched-o safe via the internal outputs FSO0 and
FSO1 (see „4.5 Block diagram“ on p.7). This allows a safety shutdown of the connected
sensors and actuators.

4.1 Intended use

The TBPN-L1-FDIO1-2IOL is a decentralized PROFIsafe safety module. It collects field signals
and transfers the signals safe to a PROFINET master.
Thanks to an extended temperature range from -40 to +70 °C and the protection class IP65/
IP67/IP69K, it can be used in harsh environments directly on the machine.
The device is specified for the operation in industrial environment. If it is used in residential or
mixing areas, radio interference may occur.

4.1.1 Foreseeable misuse

The device is not suitable for:

The use in explosive areas

■

Outdoor use

■

The permanent use in liquids

■

4.2 Device overview

30,2

60,4

24

P1

P2

230,5

218

38,8

C0C1C2C3

X1

6,3

C4C5C6C7

X2

6

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4.3 Type plate

TBPN-L1-FDIO1-2IOL

FE

V1

Ident-No.: 6814053
Charge code:
YoC:

Hans Turck GmbH & Co. KG
Witzlebenstr.7
D-45472 Mülheim a. d. Ruhr
www.turck.com

4.4 Switches and connectors

Meaning

Meaning Power IN

X2 Power OUT

C0 FDI0/1, safety input

C1 FDI2/3, safety input

C2 FDX4/5, safety in-/output

C3 FDX6/7, safety in-/output

C4

C5

C6 IOL, IO-Link port1

C7 IOL, IO-Link port2 (safe shutdown via FSO1 possible)

F-Address

P1 Ethernet 1

P2 Ethernet 2

FE Functional earth

C0

C1

C2

C3

X2X1

C4

C5

C6

C7

F-Address

P2P1

DXP8/9, standard in-/outputs
(safe shutdown via FSO0)

DXP10/11, standard in-/outputs
(safe shutdown via FSO0 possible)

Rotary coding switch for address setting for PROFIsafe (F-address
setting)

4.5 Block diagram

1

C0

5

1

C1

5

1

C2

5

C3

4

FDI0/1 FSO0

2

4

FDI2/3

2

4

FDX4/5

2

4

FDX6/7

2

(intern)

FSO1

(intern)

DXP8

DXP9

DXP10

DXP11

IO-Link Port1

DI12 (C/Q)

DXP13

IO-Link Port2

DI14 (C/Q)

DXP15

4

C4

2

4

C5

2

4

C6

2

4

C7

2

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Safety function

5 Safety function

The device provides two safe digital SIL3 inputs (FDI) and two SIL3-connectors (FDX), configu­rable as in- or outputs.

The following devices can be connected to the safety inputs:

Max. four 2-channel safety switches and sensors

■

Contact switches, e.g. Emergency stop buttons, protective door switches

■

Sensors with OSSD switching outputs with test signals

■

Sensors with OSSD switching outputs without test signals

■

The two safety SIL3 outputs can be used PP- or PM-switching

Additionally, the DXP channels (C4 and C5) as well as the second IO-Link port (C7) can be
switched-o safe via the internal outputs FSO0 and FSO1 (see „4.5 Block diagram“ on p.7).

5.1 Safe status

In the safe state the device outputs are in LOW-state (0).
The inputs report a LOW-state (0) to the logic.

5.2 Fatal Error

The following errors lead to Fatal Error and thus to the safe state:

Incorrect wiring at the output (e.g. capacitive load, energetic recovery)

■

Incorrect power supply

■

Strong EMC disturbances

■

Internal device error

■

6 Safety planning

The operator is responsible for the safety planning.

6.1 Prerequisites

 Perform a hazard and risk analysis.
 Develop a safety concept for the machine or plant.
 Calculate the safety integrity for the complete machine or plant.
 Validate the complete system.

6.2 Reaction time

If the system is operated with higher availability, the max. reaction time is extended (see „6.3

Safety characteristic data“ on p.9).

In addition to the reaction time in the device, reaction times of the further PROFIsafe compo­nents have to be considered eventually. Please find the respective information in the technical
data of the respective devices.

Further information about the reaction time can be found in the online help for the software
„Turck Safety Configurator” (see also „7.2.4 Configuring“ on p.12).

8

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6.3 Safety characteristic data

Characteristic data Value Standard

Performance Level (PL) e EN/ISO 13849-1

Safety category 4 EN/ISO 13849-1

Safety Integrity Level (SIL ) 3 IEC/EN 61508

SIL CL 3 EN/IEC 62061

PFH

D

PFD 5 × 10

MTTF

D

DC 99 %

Permissible duration of use (TM) 20 years EN ISO 13849-1

Maximum on-time 12 months IEC/EN 61508

Max. reaction time in case of shutdown

PROFIsafe > local output 25 ms IEC/EN 61508

Local input > PROFIsafe 20 ms

Local input <> local output 35 ms

7 Operating instructions

7.1 General

4 × 10 -9 1/h IEC/EN 61508; EN/ISO 13849-1

-6

> 2500 years EN/ISO 13849-1: 2016

IEC/EN 61508

 In case of a safety application, the device has to be registered under www.turck.de/SIL.
 The device must only be mounted, installed, operated and maintained by trained and quali-

fied personnel.

 The device is not specified for a certain application. Make sure that application-specific

aspects are considered.

 Before expiration of the permissible duration of use the device must be replaced (see „6.3

Safety characteristic data“ on p.9).

 Execute a functional test every twelve months.
 The device must not be repaired. If problems occur with regard to functional safety, TURCK

must be notified immediately and the device must be returned immediately to:

Hans Turck GmbH & Co. KG
Witzlebenstraße 7
45472 Mülheim an der Ruhr
Germany

 In case of device errors which lead to the safe state, measures have to be taken which guaran-

tee the safe state for the further operation of the complete control system.

 Dangerous failures have to be reported immediately to Turck.

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Operating instructions

7.2 Before operation

The operator of the machine or the plant in which the safety related system is used, is responsi­ble for the correct and safe overall function of every single safety component.

 Carry out a validation of the safety category for the complete system depending on the selec-

tion of the used safety components.

7.2.1 Mounting

ATTENTION

Mounting on uneven surfaces

Damage to the device due to mechanical tensions

 Mount the device onto an even mounting surface.
 Use two M6 screws to mount the device.
 Mount the device onto a pre-drilled and grounded mounting surface. The maximum

tightening torque for the screws is 1.5 Nm.

M6 (2x)
max. 1.5 Nm

218 [5.58]

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7.2.2 Connection

Connect the Ethernet

The maximum tightening torque for the Ethernet connectors is 0.6 Nm.

Connect power supply

The externally connectable circuits have to be securely disconnected from the mains supply.

ATTENTION

Loss of protection class IP65/IP67/IP69K

Damage to the device due to invasive foreign material or liquids

 Seal unused sockets, connectors and covers carefully.
 Use appropriate 7/8" sealing caps, e.g. type RKMV-CCC (not included in the scope of

delivery).

 Use appropriate M12-sealing caps (included in the scope of delivery).

 Connect the device to the field bus according to the pin assignment (see „1 About this docu-

ment“ on p.5).

WARNING

Wrong 24 V power supply unit

Dangerous voltage and loss of functional safety

 Exclusively use power supply units with PELV voltage according to EN50178 (PELV).
 Assure that the maximum output voltage of 60 V is not exceeded, even in case of an

error.

 Connect the device to the power supply according to the pin assignment (see „8 Appen-

dix: Wiring diagram“ on p.14). The female connectors at the device have the following

function:

X1: Voltage IN

ū

X2: Conduct voltage to next node

ū

Connect sensors and actuators

DANGER

Wrong supply of sensors and actuators

Danger to life due to external supply

 Guarantee that no external supply is used.
 Guarantee that the inputs are only supplied through the same 24 V source as the

device itself.

DANGER

Connection of fast reacting loads

Danger to life due to connection failures

 Use loads with mechanical or electrical inertia.

Positive and negative test pulses have to be tolerated.

The maximum tightening torque for the M12 connectors is 0.8 Nm.

 Connect the sensors and actuators to the in- and outputs according to the pin assignment

(see „8 Appendix: Wiring diagram“ on p.14).

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Operating instructions

BUS

ERR

7.2.3 Address assignment

 Set the F-address (PROFIsafe address) for the TBPN-L1-FDIO1-2IOL using the three rotary

coding switches under the cover at the device.

The module is delivered with the switch position 0. The address 0 and the addresses ≥ 900 are
no valid F-addresses.

7.2.4 Conguring

The safety function of the safe channels can only be configured via the software Turck Safety
Configurator.
After the configuration, the device generates a CRC and a configuration protocol. This protocol
has to be checked and validated by the user. The CRC is stored as reference in the configuration
of the PROFIsafe control and guarantees the correct safety function.
Further information about the software can be found in the online help.

Memory

F-Address

32

1

0

9876

x 100 x 10 x1

32

4

1

5

0

9

8 7

1

4

5

0

6

9

8 7

32

4

5

6

PROFINETETH1 ETH2

Switch position Meaning

0 State of delivery, no valid address

1…899 F-address, the setting is accepted after a device restart

900 Factory Reset: reset of the device to factory settings

901 Erase Memory Stick: deletes the content of the configuration memory

The configuration of the safe I/O channels set via the Turck Safety Configuratior is automatically
stored to a pluggable memory stick which is part of the scope of delivery. In case of a device ex­change, the device configuration can be transferred to another device using the memory stick.

12

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7.3 Operation

7.3.1 Indication elements

During operation, the LEDs have the following functions:

LED Color Meaning

ETH1

green Link established, 100 Mbps

green blinking Ethernet Traffic, 100 Mbps

yellow Link established, 10 Mbps

yellow blinking Ethernet Traffic, 10 Mbps

ETH2

PWR

ERR

BUS

green Link established, 100 Mbps

green blinking Ethernet Traffic, 100 Mbps

yellow Link established, 10 Mbps

yellow blinking Ethernet Traffic, 10 Mbps

green Voltage OK

red Power supply faulty

green No diagnostics

red Diagnostics pending

green Active connection to a master

green blinking Device ready for operation

red IP address conflict or restore mode or timeout

red blinking Blink-/wink-command active

0…3

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green/red blinking Autonegotiation and/or waiting for DHCP-/BootP-address assignment.

green Channel active

green blinking Self-test

red Discrepancy

red blinking Cross-connection

13

Appendix: Wiring diagram

P1

LED Color Meaning

4…7

green Channel active

green blinking Self-test (input only)

red Discrepancy, overload (output only)

red blinking Cross-connection

8…11

green Channel active

red Overload (output only)

red blinking Channel inactive (input only), overload of supply

green permanent,

Channel active and overload of supply (input only)

red blinking

12…15 green IO-Link communication or DI active

red Error

0…7

red all blinking

Fatal Error

alternating

WINK

white flashing Helps to localize the module if the Blink/Wink command is active.

7.3.2 Output error behavior

In case of an error a switched-off output can be switched on for ≤ 1 ms.

7.3.3 Decommissioning

The decommissioning is described in the user manual (D301379).

8 Appendix: Wiring diagram

The pin assignments can be found on the side of the device.

8.1 Ethernet

v

2

1

4

v

2

1

4

P2

3

flange = FE

3

flange = FE

1 = TX +
2 = RX +
3 = TX –
4 = RX –

1 = RX +
2 = TX +
3 = RX –
4 = TX –

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8.2 Power supply

wv

1 BK = GND V2

3

2 BU = GND V1

452

3 GNYE = FE
4 BN = 24 VDC V1

1

5 WH = 24 VDC V2

X1 X2

8.3 Safety inputs

v

1 = V

2

2 = FDI (T2)

4

3 = GND (V1)
4 = FDI (T1)
5 = T2

13

5

8.4 Safety in-/outputs

v

1 = V

2

2 = FDO-/FDI (T2)

4

3 = GND (V1)
4 = FDO+/FDI (T1)
5 = T2

13

5

aux

aux

1/T1

1/T1

3

4

2

5

1

8.5 DXP

8.6 IO-Link

NOTE

For PM-switching outputs, connect the negative pole of the load to the M-connector
of the respective output (pin 2).

v

1 = FSO0

2

2 = DI/DO

4

v

2

4

3 = GND (V1)
4 = DI/DO
5 = FE

1 = V
2 = DI/DO
3 = GND (V1)
4 = C/Q
5 = GND (V1)

13

5

13

5

aux

1/FSO1

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Appendix: Connection examples

9 Appendix: Connection examples

9.1 Inputs

Safe equivalent inputs for potential free contacts (NC/NC)

1 T1

2 FDI (T2)

3 n.c.

4 FDI (T1)

5 T2

TBPN-L1…

Safe antivalent input for potential free contacts (NC/NO)

1 T1

2 FDI (T2)

3 n.c.

4 FDI (T1)

5 T2

TBPN-L1…

Safe electronic input (OSSD)

OSSD

+

–

1 VAUX1

2 FDI (T2)

3 GND

4 FDI (T1)

5 n.c.

TBPN-L1…

1 T1

2 FDI (T2)

3 n.c.

4 FDI (T1)

5 T2

TBPN-L1…

9.2 Outputs

Safe output PP-switching

TBPN-L1…

1 n.c.

2 n.c.

3 GND (V1)

4 FDO +

5 n.c.

Safe output PM-switching

TBPN-L1…

1 n.c.

2 FDO –

3 n.c.

4 FDO +

5 n.c.

For PP-switching outputs, connect the negative pole
of the load to the GND of the respective output (pin 3).
Another connection to the GND of the power supply
unit is not permitted!
The wiring has to allow an exclusion of faults regard­ing cross connection.

For PM-switching outputs, connect the negative
pole of the load to the M-connector of the respective
output (pin 2).

16

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10 Appendix: Designations and abbreviations

Abbreviation Meaning

DC Diagnostic Coverage

E/E/PE-system Electrical/electronic/programmable electronic system

HFT Hardware failure tolerance

MTTF

d

PFD Probability of dangerous failure on demand

PFH Average frequency of dangerous failure per hour

PL Performance Level

SIL Safety Integrity Level

Mean Time To Failure Dangerous

11 Appendix: Function tests

Ensure that the function test is only carried out by qualified personnel.
A suggested function test consists of the following steps:

Step Action

1 Switch every safety related input at least once a year.

2 Control the switching behavior by monitoring the output circuits.

3 Observe the maximum duty cycle and the total operation time depending on the select-

ed PFD value.

4 If the maximum duty cycle is reached: request the shutdown function in order to check

the function of the safety system

Once the test has been completed, document and archive the results.

12 Appendix: Document history

Version Date Modications

1.0 2016-06-30 First version

2.0 2018-01-17 – Safety characteristic data updated
–Connection examples extended

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17

Appendix: Technical data

13 Appendix: Technical data

Device

Technical data TBPN-L1-FDIO1-2IOL

Ident no. 6814053

YoC 2016

Interfaces

PROFINET 2 x M12, 4-pin, D coded

Service interface Ethernet

Power supply

V1 (incl. electronics supply) 24 VDC

V2 24 VDC, only through connected

Permissible range 20.4...28.8 VDC

Isolation voltages ≥ 500 VAC

Times

Internal delay time
(for calculating the Watchdog time)

Reaction times see „6.3 Safety characteristic data“ on p.9

Safety inputs for potential free contacts

Loop resistance <150 Ω

Max. cable length max. 1 μF at 150 Ω

Test pulse typ. 0.6 ms

Test pulse max. 0.8 ms

Interval between 2 test pulses 900 ms (for static inputs)

Safety inputs for OSSD

Signal voltage, low level EN 61131-2, type 1 (< 5 V; < 0,5 mA)

Signal voltage, high level EN 61131-2, type 1 (> 15 V; > 2 mA)

Max. OSSD supply per channel 2 A

Max. tolerated test pulse width 1 ms

Min. interval between 2 test pulses 12 ms at 1 ms test pulse width

Safety outputs

Suitable for inputs according to EN 61131-2, type 1

Output level in OFF-state < 5 V

Output current in OFF-state < 1 mA

Test pulse resistive load, max. 0.5 ms

Test pulse, max. 1.25 ms

Interval between 2 test pulses, typical 500 ms

Interval between 2 test pulses, min. 250 ms

Max. output current 2 A (resistive)

10 ms

limited by line capacity

8.5 ms at 0.5 ms test pulse width

7.5 ms at 0.2 ms test pulse width

18

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Max. total current for device 9 A, derating curve:

∑

[A]

I

9

7

0

0-404070

[°C]

Max. output current 2 A, (DC-load) derating curve:

I [A]

2

1.5

0

0-404070

[°C]

The user has to provide an additional overcurrent protection on site.

General Information

Max. cable length

–Ethernet 100 m (per segment)

–Sensor/actuator 30 m

Operating/storage temperature -40 °C to +70 °C (-40 to + 158 °F)

Protection class IP65/IP67/IP69K

Housing material Fiber-glass reinforced Polyamide (PA6-GF30)

Window material Lexan

Tests

Vibration test according to EN 60068-2-6, IEC 68-2-47,

acceleration up to 20 g

Drop and topple according to IEC 60068-2-31/IEC 60068-2-32 1

Shock test according to EN 60068-2-27

Electro-magnetic compatibility according to EN 61131-2/EN 61326-3-1

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19

Appendix: Declaration of Conformity

EG Konformitätserklärung Nr.

EC Declaration of Conformity No.: / Déclaration CE de
conformité n° / Declaración CE de conformidad n.° /
Dichiarazione CE di conformità N. / deklaracji zgodności WE nr:

5126M

Wir/

We/Nous/Nosotros/Noi/My

HANS TURCK GMBH & CO KG
WITZLEBENSTR. 7
D – 45472 MÜLHEIM A.D. RUHR

erklären in alleiniger Verantwortung, dass die Produkte

declare under our sole responsibility that the products / déclarons sous notre seule responsabilité que les produits / declaramos bajo
nuestra propia responsabilidad que los productos / dichiariamo sotto la nostra esclusiva responsabilità, che I / deklaruje z pełną
odpowiedzialnością, że produkty

Safety Block I/O Modul

Safty block I/O Module / Modules de sécurité
E/S / Módulos de E/S de bloque de seguridad /
Moduli I/O di sicurezza / Kompaktowe moduły

bezpieczeństwa I/O

TBPN-L1-FDIO1-2IOL

auf die sich die Erklärung bezieht, den Anforderungen der folgenden EU-Richtlinien durch Einhaltung der
folgenden Normen genügen:

to which this declaration relates are in conformity with the requirements of the following EU directives by compliance with the following
standards: / concernés par la présente déclaration répondent aux exigences des directives européennes suivantes conformément aux
normes suivantes: / a los que hace referencia esta declaración cumplen los requisitos de las siguientes directivas de la UE ya que s on
conformes a las siguientes normas: / cui la presente dichiarazione fa riferimento, soddisfano i requisiti delle seguenti dire ttive UE in
conformità alle seguenti norme: / do których odnosi się ta deklarcja, spełniają wymagania następujących dyrektyw UE poprzez zgodność
z następującymi normami

EMV-Richtlinie /

EMC Directive /
Directive EMC / Directiva CEM /
Direttiva EMC (compatibilità elettromagnetica) /
Dyrektywa EMC

2014 / 30 / EU

26/2/2014

EN 61000-6-2:2005

EN 61000-6-4:2007 + A1:2011

EN 61131-2:2007

Maschinenrichtlinie /

Machinery directive /
Directive machines / Directiva sobre máquinas /
Direttiva macchine / Dyrektywa Maszynowa

2006 / 42 / EC

17/5/2006

EN ISO 13849-1:2015

EN ISO 13849-2:2012

EN 62061:2005/A1:2013/A2:2015

Weitere Normen, Bemerkungen

Additional standards, remarks / Autres normes, remarques / Otras normas, observaciones / Norme aggiuntive, osservazioni / Inne
standardy, komentarze

EN 61326-3-1:2008
EN 61508-1…7:2010

Dokumentationsbevollmächtigter:

Authorized representative for documentation: / Représentant pour la
documentation: / Rappresentante per la documentazione: /
Representante para la documentación: / upoważnionego
reprezentatywne dla dokumentacji:

Dr. M. Linde
Witzlebenstr. 7
45472 Mülheim a. d. Ruhr

Nummer der EG-Baumusterprüfbescheinigung /

Number of EC Type Examination Certificate / Nom du certificat d'examen
de type CE / Número del certificado de examen CE de tipo / Numero del
certificato di esame CE del tipo / numer świadectwa badania typu WE

44 205 16 045401

Benannte Stelle /

Notified body / Organisme notifié / Organismo notificado / Organismo
notificato / Jednostka notyfikowana

0044
TÜV NORD CERT GmbH
Langemarckstraße 20
45151 Essen, Germany

Mülheim, 29.06.2016

i.V. Dr. M. Linde,

Leiter Zulassungen / Manager Approvals / Responsable des

autorisations / Director de aprobaciones / Direttore Omologazioni / Kierownik

Ort und Datum der Ausstellung /

Place and date of issue / Lieu et date
d'émission / Lugar y fecha de expedición /
Luogo e data del rilascio / Miejsce i data
wydania

Name, Funktion und Unterschrift des Befugten /
Name, function and signature of authorized person /
Nom, fonction et signature de la personne autorisée /
Nombre, cargo y firma del autorizado /
Nome e funzione della persona autorizzata /

Nazwisko, stanowisko i podpis osoby upoważnionej

14 Appendix: Declaration of Conformity

20

Hans Turck GmbH & Co. KG | T [phone] | F [phone] | [e-mail] | www.turck.com

D301391 | 2018/01

*D301391ßß1801*

28 subsidiaries and over

60 representations worldwide!

www.turck.com