Beckhoff Automation (www.beckhoff.com) unveiled its latest EtherCAT Terminals with embedded Safety Programmable logic controller (“PLC”) for a flexible, compact and powerful safety solution, the TwinSAFE Terminals for the EtherCAT I/O system. With simple safety I/O terminals, it helps machine manufacturers and builders streamline safety systems. Conforming to EN ISO 13849-1 PL e and IEC 61508 and rated for SIL 3, TwinSAFE Terminals for EtherCAT I/O system are certified for use across the US.

The latest safety terminals for the EtherCAT I/O system fully utilize the high-performance EtherCAT. EL6900 safety PLC terminal can process 256 safety-relevant function blocks and is capable of integrating up to 128 four-channel safety terminals (“512 safety devices”). The integrated safety function blocks in the EL6900 Safety PLC are set up according to each unique application. Through this, safety functions can be simply programmed like latches, timers, serial/parallel muting, two-hand control, emergency stop and safety door monitoring. A connection shutdown function can also be established so the equipment’s interchangeable sections with embedded safety terminals can be detached from the machine without causing any safety system errors.

With additional EL6900 Safety PLCs, systems can be expanded as necessary. Through this, the safety-relevant control tasks for plants and machines can be implemented centrally or locally according to the application. The 24V DC digital output terminals (“EL2904: 0.5A and EL2902: 2.3A”) and 24V DC digital input terminals (“EL1904”) are available for connecting safety actuators or sensors. The TwinSAFE Terminals can be set up in any position in distributed I/O systems and in the terminal system. Also, the EL6900 Safety PLC can be used for AX5000 Servo Drives from Beckhoff as a safety controller that uses EtherCAT as a motion bus.

Safety over EtherCAT(“TM”) allows the integration of safety devices to a control system without requiring segregated safety network or a stand-alone safety PLC. Safety data is handled through a black channel passing a standard Ethernet cable. This new safety solution integrated in the terminal block housing is exceptionally compact, providing the highest flexibility through nearly limitless positioning inside the EtherCAT Terminal systems. The standard EtherCAT I/O Terminal systems can be intermixed to the same node with the safety terminals.

The Beckhoff TwinSAFE, a proven safety solution, has been successfully integrated into the original Beckhoff Bus Terminal I/O system (“K-bus”) and is in use around the world in a broad range of applications. The integrated TwinSAFE technology in the EtherCAT Terminal system (“E-bus”), the high performance of EtherCAT – with enhanced diagnostics and ultra fast communication – is now available.

Safety applications can be optionally made by using simple configuration in TwinCAT software in System Manager or programmed using a TwinCAT PLC (IEC 61131-3), in case of more complex applications. The Safety PLC’s safety-relevant parameters are available in TwinCAT software and can be utilized in the standard controller. Also, typical drive functions can be linked and selected very simply.

The EL6900 Safety PLC terminal is easy and quick to replace in case of possible required service without explicitly reloading and verifying the program. The system automatically loads and verifies the configuration to dispense trouble-prone removable media. The project’s manual saving or loading is not anymore necessary in case of service.

Another feature is the integrated tool in TwinCAT for determining and calculating the PL or SIL according to EN ISO 13849-1 and EN IEC 62601. The transfer of information to an additional tool and the safety application’s previous complicated analysis are no longer required, which can lead to significant cost savings and work reductions.