1. New Automation Technology
TwinSAFE

2. Beckhoff TwinSAFE: safety and standard I/O in one system

3. TwinSAFE-Features
totally integrated in the Beckhoff busterminal system
easy to use out of the Beckhoff TwinCAT System
same modularity like the standard bus terminals
supported for PROFIBUS, RT Ethernet, EtherCAT etc.
certified IEC61508, EN954, ISO13849, etc.
TwinSAFE

4. Advantages of TwinSAFE
reduces the wiring expenditure
shortens project engineering and start-up
reduces the expenditure of a plant extension or concatenation
increases the flexibility
small space requirement: 12 mm or 24 mm width
TwinSAFE communication protocol is open for all bus systems
TwinSAFE

5. Safety engineering in modern automation
mixed network for standard and safety functions
standard network with a decentralized safety island
separate networks for standard and safety functions
TwinSAFE

6. Plant concatenation with TwinSAFE
Machine „A“
Machine „B“
Machine „C“
TwinSAFE data
TwinSAFE data
TwinSAFE

7. TwinSAFE system configuration KL1904: Safety terminal, 24 V DC
4 safety inputs and 4 clock outputs
developed and certified in accordance with
IEC/EN up to SIL 3
EN 954 up to Cat. 4
ISO/EN 13849–1 up to PL e
high diagnosis
Communication error
Processor error
Sensor error (external supply, transverse conclusion etc..)
TwinSAFE

8. TwinSAFE system configuration KL2904: Safety Output terminal 0,5 A 24 V DC
4 safety outputs
developed and certified in accordance with
IEC/EN up to SIL 3
EN 954 up to Cat. 4
ISO/EN 13849–1 up to PL e
high diagnosis
Communication error
Processor error
Actuator error
-K2
-K1
-K4
-K3
TwinSAFE

9. TwinSAFE system configuration KL6904: Safety Logic-Terminal 0,5 A 24 V DC
4 safety outputs
developed and certified in accordance with
IEC/EN up to SIL 3
EN 954 up to Cat. 4
ISO/EN 13849–1 up to PL e
high diagnosis
Communication error
Processor error
Actuator error
-K2
-K1
-K4
-K3
TwinSAFE

10. KL6904 diagnostic functions of the safe output terminal
Actuator diagnosis
Short-circuit
Wire break
wrongly external supply wires
Terminal diagnosis
Undervoltage
Overvoltage
Temperature monitoring
internal equipment diagnosis
- K1
TwinSAFE

11. KL1904 diagnostic functions of the safe output terminal
Sensor diagnosis
Short-circuit
Wire break
wrongly external supply wires
Terminal diagnosis
Undervoltage
Overvoltage
Temperature monitoring
internal equipment diagnosis
TwinSAFE

12. S-address of KLx904 S-address has to be set for each terminal
The S-address has to be unique inside a system manager configuration
S-address is binary coded (range from 1 to 1023 possible)
in this example address 242 is set
TwinSAFE

13. Communication between TwinSAFE terminals
KL6904
KL1904
TwinSAFE message from KL6904 to KL1904 (Master-Message)
TwinSAFE message from KL1904 to KL6904 (Slave-Message)
fieldbus
TwinSAFE

14. FAQ How many inputs and outputs can be used together with one KL6904?
The logic terminal can be configured that you can use up to 31 connections. It will be shipped per default with 7 connections. A change of the terminal that it can handle up to 15 connections can be done from within a PLC program. One connection is 4 Inputs (KL1904) or 4 Outputs (KL2904).
Which TwinCAT version is needed to be able to run TwinSAFE?
TwinCAT 2.10 Build installation of the TwinSAFE verifier (both installations available on Beckhoff CD 12/2006).
Can TwinSAFE be used on non-TwinCAT PLCs?
This is possible in principle, but it is not release at the moment. The customer has to program the transfer of the TwinSAFE telegrams inside his PLC and must use a TwinCAT system to do the download of the TwinSAFE configuration. It is planned to have the possibility to create a mapping list out of the system manager.
TwinSAFE

15. FAQ Things to keep in mind:
BC and BX can not be used together with TwinSAFE terminals
DeviceNet, CANopen, INTERBUS, Sercos, Modbus, Seriell are not supported. DeviceNet and CANopen is planned to be supported in the future.
The download of the TwinSAFE configuration by using the serial interface of the coupler ist currently not possible.
Light curtains and laser scanner can only be connected by using contactors. The direct connection to the input terminals is in preparation.
proximity switches can be used together with our input terminals, but it has to be assured that they are not powered during the TwinSAFE startup process.
TwinSAFE

16. Available bus couplers and firmware versions
Currently available (01/2007):
BK3120 Firmware BD00 (Release)
BK3150 Firmware B500 (Release)
BK2020 Firmware B2E2
BK1120 Firmware B700 (Release)
BK9000 Firmware BA00 (Release)
BK9100 Firmware B100 (Release)
CX9000 Image (Release)
CX1000 with CX1100 Firmware B600 (Release)
CX1020 with CX1100 Firmware B600 (Release)
TwinSAFE

17. Practice
TwinSAFE

18. Step-by-Step description of the TwinSAFE parametrisation

19. Step 1: TwinSAFE terminals will be configured in the System Manager
standard busterminal
TwinSAFE busterminal
TwinSAFE

20. Step 2a: Settings of the KL1904
TwinSAFE

21. Step 2b: Settings of the KL2904
TwinSAFE

22. Step 2c: Settings of the KL6904
TwinSAFE

23. Step 3: Append a TwinSAFE Group
A group consists of TwinSAFE terminals which are logically connected to one KL6904
Communication errors inside this group results in the switching off of only this group. Other groups are not influenced.
TwinSAFE

24. Step 4: Adding a function block
TwinSAFE

25. Step 5: Direct allocation of the inputs and outputs with the System Manager
TwinSAFE

26. Safety applications realized by certified function blocks
Example: Emergency Stop
Configure input settings
Restart
E-Stop Inputs
Output
EDM for feedback circuits
Delayed Output
Further FB‘s: Guard door monitoring, operating mode selection, AND, OR, etc..
TwinSAFE

27. Configure input settings
Break contact
Signal value 1 – Output 1 (run)
Signal value 0 – Output 0 (safe)
Make contact
Signal value 0 – Output 1 (run)
Signal value 1 – Output 0 (safe)
TwinSAFE

28. Connections
Connections will be created automatically when an input or output is used in a function block configuration inside that group
TwinSAFE

29. Step 6: Load a TwinSAFE project

30. Step 7: Verify and start the project
TwinSAFE

31. Diagnosis KL6904 Diagnosis: Internal temperatures Error codes of µC1
TwinSAFE

32. Diagnosis TwinSAFE group
Diagnosis online:
Group state
Run/Stop of group
ErrAck Signal
Error at one of the FBs
Communication error
Output error
TwinSAFE

33. Diagnosis function block list
FB number
FB type
FB state
Diagnosis bits
TwinSAFE

34. Diagnosis bits for function blocks
Diagnosis-Bits of Emergency-Stop:
Index 0-3: Discrepancy error (index 0 means inputgroup 1, index 3 means inputgroup4)
Index 4-5: EDM error (index 4 means EDM1, index 5 means EDM2)
Diagnosis-Bits of Machine Monitor:
Index 0-1: Discrepancy error MonIn (index 0 means inputgroup 1, index 1 means inputgroup 2)
Index 2: Discrepancy error Secure inputs
Diagnosis-Bits Operation Mode:
Index 0: Discrepancy error
All other FBs (AND, OR, DECOUPLE) have no additional diagnosis flags
TwinSAFE

35. Diagnosis for TwinSAFE connections
Connection number
Connection type
Master
Slave
State
Diagnosis flags
TwinSAFE

36. Diagnosis bits for TwinSAFE connection
Diagnosis bits of connection:
Bit 0: (unexpected) Null-message received (e.g. when the K-Bus or fieldbus was interrupted)
Bit 1: invalid K-Bus state
Bit 2: watchdog expired
Bit 3: CRC2-error
Bit 4: SeqNo-error
Bit 5: Slave-error (error bits (Comm_Fault, WD_Fault) in the F_Status are set)
Bit 6: F- and I-Parameter are transmitted
Bit 7: ActivateFV-Bit in F_Control is set
TwinSAFE

37. Configuration of a connection between two KL6904 by using network variables
TwinSAFE

38. Network variables Create network variables as unicast
Add a variable as Master_Message or Slave_Message
For one connection you need one publisher and one subscriber on each side.
TwinSAFE

39. Append TwinSAFE structure

40. Settings of TwinSAFE structure
S-address of the communication partner must match
Watchdog time must be identical on both sides of the connection
TwinSAFE

41. Attach TwinSAFE structure

42. Mapping of the TwinSAFE signals into the PLC

43. Mapping of TwinSAFE signals into the PLC
TwinSAFE in- and outputs:
Will be linked inside the TwinSAFE project to a PLC input variable
In the future there will be a diagnosis FB which maps all inputs and outputs directly to the PLC program.
TwinSAFE

44. User administration and version history
TwinSAFE

45. User administration and version history
TwinSAFE

46. User administration and version history
Create user…
Save TwinSAFE project…
Stored in the history…
TwinSAFE

47. export / import of the TwinSAFE project

48. Export
Choose export…
Save in xml file…
TwinSAFE

49. Import Choose import… Restoring of the connections…
Restoring of links…
TwinSAFE

50. Examples
TwinSAFE

51. networked application
Master Slave
AmsNetID
Master Slave
AmsNetID
Master Slave
AmsNetID
Pub ID 10
Sub ID 10
Publisher MASTER_MESSAGE
Subscriber MASTER_MESSAGE
Sub ID 11
Pub ID 11
Subscriber SLAVE_MESSAGE
Publisher SLAVE_MESSAGE
Pub ID 10
Sub ID 10
Publisher MASTER_MESSAGE
Subscriber MASTER_MESSAGE
Sub ID 11
Pub ID 11
Subscriber SLAVE_MESSAGE
Publisher SLAVE_MESSAGE
TwinSAFE

52. Example: Emergency stop
TwinSAFE

53. Example: Guard door monitoring
TwinSAFE

54. Example: Emergency stop and protective door
TwinSAFE

55. Questions regarding TwinSAFE?