Beckhoff TwinSAFE EL1904 Operating Instructions Manual
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Beckhoff TwinSAFE EL1904 Operating Instructions Manual

Beckhoff TwinSAFE EL1904 Operating Instructions Manual

Terminal with 4 digital fail-safe inputs
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Operating Instructions | EN
EL1904
TwinSAFE Terminal with 4 digital fail-safe inputs
2024-12-17 | Version: 3.3.0

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  • Page 1 Operating Instructions | EN EL1904 TwinSAFE Terminal with 4 digital fail-safe inputs 2024-12-17 | Version: 3.3.0...

  • Page 3: Table Of Contents

    Table of contents Table of contents 1 Notes on the documentation........................ 5 Disclaimer............................ 5 1.1.1 Trademarks ........................ 5 1.1.2 Patents .......................... 5 1.1.3 Limitation of liability ...................... 6 1.1.4 Copyright.......................... 6 Documentation issue status ...................... 7 Version numbers of the documentation ....................  9 ................................ 10 Version history of the TwinSAFE product ..................
  • Page 4 Table of contents Electrical installation........................ 38 6.3.1 Overvoltage protection .....................  38 6.3.2 EL1904 pin assignment.................... 39 6.3.3 Connecting ........................ 39 6.3.4 Connections ........................ 42 6.3.5 Signal cables........................ 44 TwinSAFE reaction times ........................  46 Tested EL1904 devices........................ 47 7 Operation .............................. 48 Environmental conditions ........................

  • Page 5: Notes On The Documentation

    Notes on the documentation Disclaimer Beckhoff products are subject to continuous further development. We reserve the right to revise the operating instructions at any time and without prior announcement. 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 these operating instructions.

  • Page 6: Limitation Of Liability

    Modifications and changes to the hardware and/or software configuration that go beyond the documented options are prohibited and nullify the liability of Beckhoff Automation GmbH & Co. KG. The following is excluded from the liability: •...

  • Page 7: Documentation Issue Status

    • First release Currentness Check whether you are using the current and valid version of this document. The current version can be downloaded from the Beckhoff homepage at http://www.beckhoff.com/twinsafe. In case of doubt, contact Support and Service [} 14]. EL1904 Version: 3.3.0...
  • Page 8 The original documentation is written in German. All other languages are derived from the German original. Product features Only the product properties specified in the current operating instructions are valid. Further information given on the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative. Version: 3.3.0 EL1904...

  • Page 9: Version Numbers Of The Documentation

    Notes on the documentation Version numbers of the documentation Version Comment 3.3.0 • Machinery Directive changed to Machinery Regulation • References to EN 61511 added • Chapter renamed to “Version numbers of the documentation” • Test pulses added to the “Signal cables” chapter and wire size width added to the “Connecting” chapter •...

  • Page 10: Version History Of The Twinsafe Product

    Product features Only the product properties specified in the current operating instructions are valid. Further information given on the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative. Version history of the TwinSAFE product This version history lists the software and hardware version numbers.

  • Page 11: References

    Notes on the documentation References Version Description Not used. Not used. 1.4.1 or newer Operating Manual for EL6910 TwinSAFE Logic Module The document contains a description of the logic functions of the EL6910 and its programming. 3.1.0 or newer Dokumentation TwinSAFE-Logic-FB The document describes the safety-related function blocks that are available in the EL6910 and thus also in the TwinSAFE card and form the safety-related application.

  • Page 12: Staff Qualification

    Notes on the documentation Staff qualification These operating instructions are intended exclusively for trained specialists in control technology and automation with the relevant knowledge. The trained specialist personnel must ensure that the applications and use of the described product meet all safety requirements.

  • Page 13: Safety And Instruction

    Notes on the documentation Safety and instruction Read the contents that refer to the activities you have to perform with the product. Always read the chapter For your safety [} 16] in the operating instructions. Observe the warnings in the chapters so that you can handle and work with the product as intended and safely.

  • Page 14: Support And Service

    Please contact your Beckhoff branch office or representative for local support and service on Beckhoff products! The addresses of Beckhoff's branch offices and representatives round the world can be found on our internet page: www.beckhoff.com You will also find further documentation for Beckhoff components there.

  • Page 15: Notes On Information Security

    1.10 Notes on information security The products of Beckhoff Automation GmbH & Co. KG (Beckhoff), insofar as they can be accessed online, are equipped with security functions that support the secure operation of plants, systems, machines and networks. Despite the security functions, the creation, implementation and constant updating of a holistic security concept for the operation are necessary to protect the respective plant, system, machine and networks against cyber threats.

  • Page 16: For Your Safety

    • ISO 13849-1, Safety of machinery – Safety-related parts of control systems – Part 1: General principles for design Beckhoff is not responsible for the safe operation of the system. No disposal in domestic waste Products marked with a crossed-out waste bin must not be disposed of with domestic waste.

  • Page 17: Safety Image Signs

    For your safety Safety image signs Beckhoff products feature safety pictograms, either on stickers or printed, which vary depending on the product. They serve to protect people and to prevent damage to the products. Safety pictograms may not be removed and must be legible for the user.

  • Page 18: General Safety Instructions

    Engineering tools allowed are TE9000 - TwinCAT 3 Safety Editor and TE9200 - TwinSAFE Loader. Use only the latest versions of the engineering tools. You will find this on the Beckhoff website. Procedures or engineering tools that deviate from this are not covered by the certificate. This is especially true for externally generated xml files for the TwinSAFE import.

  • Page 19: After Operation

    For your safety 2.3.3 After operation De-energize and switch off components before working on them Check all safety-relevant equipment for functionality before working on the TwinSAFE component. Secure the working environment. Secure the machine or plant against being inadvertently started up. Observe the chapter Decommissioning [} 62].
  • Page 20 For your safety Observe the safe state of the application The safe state of the application must be the de-energized state (quiescent current principle). The safe state of the TwinSAFE component is always the de-energized and switched off state. 2.3.4.2 Environmental conditions Observe the following ambient conditions: For indoor use...

  • Page 21: Product Overview

    Product overview Product overview Product description The EL1904 is a digital input terminal for encoders with potential-free contacts for 24 V . The bus terminal has 4 fail-safe inputs. With two-channel connection, the TwinSAFE component meets the requirements of IEC 61508:2010 (SIL 3), EN ISO 13849-1:2023 (Cat 4, PL e), IEC 61511 (SIL 3), NRTL, UL508, UL1998 and UL991. The TwinSAFE Terminal has the typical design of an EtherCAT Terminal.

  • Page 22: Block Diagram Of The El1904

    Product overview Block diagram of the EL1904 Fig. 2: Block diagram of the EL1904 The block diagram shows the basic configuration of a channel in the EL1904. The part with a red border is present four times in the terminal. Version: 3.3.0 EL1904...

  • Page 23: Laser Image

    Product overview Laser image Fig. 3: EL1904 Laser image Item number Explanation Mark of conformity for ATEX Number of the EC type examination certificate in accordance with Annex IV, paragraph A of Directive 2014/33/EU Supply voltage Mark of conformity • CE •...

  • Page 24: Intended Use

    The functions allow the Beckhoff TwinSAFE components to be used in the field of machine safety and as safety devices for the process industry. The intended field of application for TwinSAFE components is safety functions on machines and process control technology in accordance with EN 61511 and the directly associated tasks in industrial automation.

  • Page 25: Technical Data

    Technical data Technical data Product data The current certificates of all TwinSAFE products with the underlying standards and directives can be found at https://www.beckhoff.com/en-en/support/download-finder/certificates-approvals/. Hardware data Explanation Electrotechnical data • Supply voltage 24 VDC (- 15 % / + 20 %) According to IEC 61508-1:2010. (A 10 A fuse should be provided...

  • Page 26: Target Failure Measures

    Chapter 7.4.4.1.2 and 7.4.4.1.3. Environmental conditions Beckhoff products are designed for operation under certain environmental conditions, which vary according to the product. The following specifications must be observed for operation and environment in order to achieve the optimum service life of the products as well as to ensure product safety.
  • Page 27 Technical data WARNING Do not use TwinSAFE components under the following operating conditions: • under the influence of ionizing radiation (exceeding the natural background radiation) • in corrosive environments • in an environment that leads to unacceptable contamination of the TwinSAFE component A corrosive environment exists when corrosion damage becomes apparent.
  • Page 28 Technical data Permissible requirements for Explanation the environment • Correct installation position Mounted horizontally on a See chapter Installation position mounting rail [} 33]. Temperatures Tested according to IEC 60068-2-1:2007, IEC 60068-2-2:2007 and IEC 60068-2-14:2009. The measuring device has a tolerance range of ± 3 °C for the minimum temperature and ± 2 °C for the maximum temperature.

  • Page 29: Characteristic Curve Of The Inputs

    Technical data Characteristic curve of the inputs The characteristic curve of the inputs is similar to type 3 according to EN 61131-2. Fig. 4: Characteristic curve of the inputs Dimensions Fig. 5: Dimensions of the EL1904 Width: 12 mm (side-by-side installation) Height: 100 mm Depth: 68 mm EL1904 Version: 3.3.0...

  • Page 30: Lifetime

    Technical data Lifetime TwinSAFE components have a lifetime of 20 years, during which the target failure measures are guaranteed. For more information, see chapter Target failure measures [} 26]. The lifetime starts from the date of manufacture according to the Date Code. WARNING Replace TwinSAFE component after 20 years After a lifetime of 20 years, the target failure measures are no longer guaranteed.

  • Page 31: Transport And Storage

    The TwinSAFE components can be stored for shorter or longer periods. Observe the conditions specified in chapter Environmental conditions. Check the seal for damage Check the barcode sticker used to seal the outer packaging for damage. If the sticker is missing, opened or damaged, contact Beckhoff Support and Service. EL1904 Version: 3.3.0...

  • Page 32: Installation

    Installation Installation Safety instructions Before installing and commissioning the TwinSAFE components read the safety instructions in this documentation. Mechanical installation WARNING Only work in a de-energized state The bus terminal system is under tension. Bring the bus terminal system into a safe, de-energized state before starting installation, disassembly or wiring of the TwinSAFE component.

  • Page 33: Installation Position

    07 08 PE PE EL1904 BECKHOFF Fig. 8: Installation position • All figures in millimeters Mount the mounting rail horizontally for the prescribed installation position. The connection surfaces of the EL terminals or KL terminals must point to the front. This can be seen in the figure below.

  • Page 34: Arrangement Instructions

    EL1904 EL1904 EL1904 EL3102 EL1904 EL3102 EL1904 EL6900 EL1904 EL1104 EL9410 EL1904 EL1104 EL1904 EL2904 EL1904 EL1904 EL2008 EL1904 EL6900 BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF...

  • Page 35: Fig. 10 Thermally Poor Arrangement

    EL1904 EL1904 EL1904 EL3102 EL1904 EL3102 EL1104 EL1904 EL1904 EL1104 EL9410 EL6900 EL1904 EL1904 EL2904 EL1904 EL1904 EL2008 EL1904 EL2008 BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF...

  • Page 36: Sample Configuration For Temperature Measurement

    EL1104 EL1104 EL1904 EL1904 EL1904 EL3102 EL1904 EL3102 EL1904 EL4112 EL6900 EL9110 EL1904 EL2904 EL1904 EL9110 EL1904 EL2008 EL1904 EL2008 BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF BECKHOFF...
  • Page 37 Installation Ensure a functional component connection Observe the assembly sequence described. First connect adjacent TwinSAFE components together using tongue and groove. Only slide the TwinSAFE component onto the mounting rail after it has been plugged together. If the tongue and groove do not interlock, a functional connection will not be established. When correctly assembled, no significant gap should be visible between the housings.

  • Page 38: Electrical Installation

    Installation 2. Push the TwinSAFE Terminal [3] together with the adjacent component with tongue and groove 3. Push the TwinSAFE Terminal [3] against the mounting rail [1] until the locking mechanism audibly engages on the mounting rail Electrical installation 6.3.1 Overvoltage protection Provide a surge filter against overvoltage for the supply voltage of the bus terminal block and the TwinSAFE components if protection against overvoltage is required in your system.

  • Page 39: El1904 Pin Assignment

    Installation 6.3.2 EL1904 pin assignment Fig. 12: EL1904 pin assignment Terminal point Input Signal Input 1+ Input 1- Input 3+ Input 3- Input 2+ Input 2- Input 4+ Input 4- Configurable inputs The inputs 1 to 4 can be occupied as you want with normally closed contacts or normally open contacts.
  • Page 40 Installation Wire size width (conductors with a wire end 0,14 to 1,5 mm sleeve) Wire stripping length 8 to 9 mm 6.3.3.1 Conductor with ferrule Solid and fine-stranded conductors with ferrules can be inserted directly into the terminal point without actuation. For all other ladder types, follow the instructions in the following chapter. 6.3.3.2 Other conductors Up to 16 terminal points enable the connection of solid or fine-wire cables to the TwinSAFE component.
  • Page 41 Installation 3. Insert the wire [3] into the round terminal opening 4. Pull the screwdriver [2] out of the opening The terminal [1] closes automatically when the pressure is released. The wire [3] is held securely and permanently. The permissible conductor cross-section can be found in the technical data.

  • Page 42: Connections

    Installation 6.3.4 Connections The electrical connections between the TwinSAFE components are realized automatically by plugging the components together. 6.3.4.1 Spring contacts of the E-bus NOTICE Observe the E-bus current Observe the maximum current that your EtherCAT Coupler can supply to the E-bus. Use the EL9410 Power Supply Terminal if the current consumption of your TwinSAFE Terminals exceeds the maximum current that your EtherCAT coupler can supply for the E-bus supply.

  • Page 43: Power Contacts

    Installation Output side +5VDC supply voltage of the E-bus 0 VDC ground of the E-bus supply voltage Transmission line TX + Transmission line TX - Receive line RX + Receive line RX - 6.3.4.2 Power contacts Note the connection of the power contacts During the design of a bus terminal block, note the contact assignments of the individual TwinSAFE components, as some components do not loop through the power contacts or do not loop them through completely.

  • Page 44: Signal Cables

    Installation 6.3.5 Signal cables Permitted cable length Fig. 13: Permitted cable length When connecting a single switching contact via its own continuous cabling (or via a non-metallic sheathed cable), the maximum permitted cable length is 100 m. The use of contact points, connectors or additional switching contacts in the cabling reduces the maximum propagation.

  • Page 45: Fig. 14 Typical Course Of Test Pulses Of The Inputs

    Installation Fig. 14: Typical course of test pulses of the inputs If self-testing sensors are to be used on the safe inputs, please refer to chapter Configuration for light barriers, light grids, light curtains etc [} 55]. EL1904 Version: 3.3.0...

  • Page 46: Twinsafe Reaction Times

    Installation TwinSAFE reaction times The TwinSAFE terminals form a modular safety system that exchanges safety-oriented data via the Safety- over-EtherCAT protocol. This chapter is intended to help you determine the system's reaction time from the change of signal at the sensor to the reaction at the actuator. Typical response time The typical response time is the time required for transferring a piece of information from the sensor to the actuator, when the whole system operates normally, without error.

  • Page 47: Tested El1904 Devices

    Installation Fig. 16: Worst case response time It is assumed that a signal change takes place at the sensor, and that this is passed to the input. A communication error occurs just at the moment when the signal is to be passed to the communication interface.

  • Page 48: Operation

    80°C at the wire branching points, then cables must be selected whose temperature data correspond to the actual measured temperature values! Observe the permissible ambient temperature range of 0 to 55 °C when using Beckhoff fieldbus components in potentially explosive atmospheres!

  • Page 49: Identification

    • EN 60079-15: 2005 7.2.2 Identification Beckhoff fieldbus components that are certified for use in potentially explosive atmospheres bear one of the following markings: II 3 G Ex nA IIC T4 Gc KEMA 10ATEX0075 X Ta: 0 … 55 °C II 3 G Ex nA nC IIC T4 Gc KEMA 10ATEX0075 X Ta: 0 …...

  • Page 50: Further Atex Documentation

    Inserting a Bus Terminal See TwinCAT automation software documentation. 7.3.3 Inserting an EL1904 An EL1904 is inserted in the same way as any other Beckhoff Bus Terminal. In the list open Safety Terminals (ELx9xx) and select the EL1904. Version: 3.3.0 EL1904...

  • Page 51: Fig. 17 Inserting An El1904

    Operation Fig. 17: Inserting an EL1904 EL1904 Version: 3.3.0...

  • Page 52: Address Settings On Twinsafe Terminals With 65535 Possible Addresses

    Operation 7.3.4 Address settings on TwinSAFE terminals with 65535 possible addresses Fig. 18: Address settings on TwinSAFE terminals with 65535 possible addresses Set the TwinSAFE address for the terminal using the two dip switches (with 8 setting options) on the left- hand side of the EL1904 TwinSAFE terminal.

  • Page 53: Entering A Twinsafe Address And Parameters In The System Manager

    Operation 7.3.5 Entering a TwinSAFE address and parameters in the System Manager The TwinSAFE address set at the DIP switch must also be entered in tab FSoE (under FSoE address) under the EL1904. Fig. 19: Entering the FSoE address The EL1904 parameters are set under the respective TwinSAFE connection in the Connection and Parameter tabs.

  • Page 54: Fig. 20 Setting The Connection Of The Twinsafe Connection

    Operation Fig. 20: Setting the connection of the TwinSAFE connection Fig. 21: Setting the parameters of the TwinSAFE connection Parameter overview PrmName Meaning Values FSoE_Address DIP switch address 1 to 65535 Operating Mode Digital / standstill monitoring 1 and 2 Digital / standstill 1 and 2 (Standstill monitoring is not supported) Sensor test The clock signal for connection Input1+...

  • Page 55: Fig. 22 Maximum Permissible Sensor Self-Test Duration Of 350 Μs

    Operation PrmName Meaning Values Sensor test The clock signal for connection Input3+ true / false channel 3 active is checked at connection Input3-. Sensor test The clock signal for connection Input4+ true / false channel 4 active is checked at connection Input4-. Logic channel 1 Logic of channels 1 and 2 •...
  • Page 56 Operation Connect the two sensor signals either to channels 1 and 2 or channels 3 and 4 and activate asynchronous repetition OSSD or any pulse repetition for the two inputs used under parameter Logic for channel x and y. The difference between these settings is that with any pulse repetition simultaneous tests of the OSSD signals up to 350 µs are allowed.

  • Page 57: Diagnostics

    Diagnostics Diagnostics Diagnostic LEDs The LEDs Diag 1 to Diag 4 display diagnostic information for the EL1904. 8.1.1 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 Error in S parameter (TwinSAFE parameter)

  • Page 58: Diagnostic Objects

    If another flashing code is displayed, this means that there is an internal terminal error that has stopped the terminal. In this case the terminal must be checked by Beckhoff Automation GmbH & Co. KG. Note the flashing codes and return the terminal Note the flashing code displayed and include this information with the terminal when you return it.
  • Page 59 Diagnostics Index Name Meaning Flags Default 800E:0B Error during two- Error during the contiguous evaluation of two channels, channel i.e. the two channels contradict each other. evaluation Error in the first input pair Error in the second input pair 800E:0C Error in the safety Bits Error in the input pair 1, 0 Error in the first input pair...

  • Page 60: Maintenance And Cleaning

    Maintenance and cleaning Maintenance and cleaning Cleaning by the manufacturer only Do not operate the TwinSAFE component if it is unacceptably dirty. Refer to the technical data for the protection class. Send unacceptably dirty TwinSAFE component to the manufacturer for cleaning. TwinSAFE components are basically maintenance-free.
  • Page 61 Maintenance and cleaning 3. Pull the TwinSAFE component [1] out of the bus terminal block from the mounting rail [3] with little effort EL1904 Version: 3.3.0...

  • Page 62: 10 Decommissioning

    In accordance with the WEEE-2012/19/EU directives, you can return used devices and accessories for professional disposal. The transport costs are borne by the sender. Send the used devices with the note "For disposal" to: Beckhoff Automation GmbH & Co. KG Gebäude „Service“ Stahlstraße 31...

  • Page 63: 11 Appendix

    Appendix 11 Appendix 11.1 Volatility If there are requirements concerning the volatility of products in your application, for example of the U.S. Department of Defense or similar authorities or security organizations, the following process applies: The product has both volatile and non-volatile components. Volatile components lose their data immediately after removing power.

  • Page 64: Focus Of Certificates

    The current certificates of all TwinSAFE components with the underlying standards and directives can be found at https://www.beckhoff.com/en-en/support/download-finder/certificates-approvals/. If the document refers only to the first four figures of a product (ELxxxx), the certificate is valid for all available variants of the component (ELxxxx-abcd).
  • Page 65 Table of figures Table of figures Fig. 1 EL1904 – TwinSAFE Terminal with 4 digital fail-safe inputs............Fig. 2 Block diagram of the EL1904 ....................... Fig. 3 EL1904 Laser image ........................Fig. 4 Characteristic curve of the inputs....................Fig. 5 Dimensions of the EL1904 ......................
  • Page 66 Trademark statements Beckhoff®, TwinCAT®, TwinCAT/BSD®, TC/BSD®, EtherCAT®, EtherCAT G®, EtherCAT G10®, EtherCAT P®, Safety over EtherCAT®, TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by Beckhoff Automation GmbH.
  • Page 67 More Information: www.beckhoff.com/EL1904 Beckhoff Automation GmbH & Co. KG Hülshorstweg 20 33415 Verl Germany Phone: +49 5246 9630 info@beckhoff.com www.beckhoff.com...

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