Beruflich Dokumente
Kultur Dokumente
TwinSAFE
Version: 1.6.2
Date:
2015-10-02
Table of contents
Table of contents
1 Foreword
1.1 Notes on the manual
5
5
1.1.1
Disclaimer
1.1.2
Trademarks
1.1.3
Patent Pending
1.1.4
Copyright
1.2.1
Delivery state
1.2.2
1.2.3
1.2.4
1.2.5
Explanation of terms
1.2.6
1.2.7
2 Circuit examples
2.1 ESTOP function variant 1 (Category 3, PL d)
9
9
2.1.1
2.1.2
10
2.1.3
Calculation
10
15
2.2.1
15
2.2.2
16
2.2.3
Calculation
16
21
2.3.1
21
2.3.2
22
2.3.3
Calculation
22
27
2.4.1
27
2.4.2
28
2.4.3
Calculation
28
33
2.5.1
33
2.5.2
34
2.5.3
Calculation
34
Table of contents
39
2.6.1
39
2.6.2
40
2.6.3
Calculation
40
45
2.7.1
45
2.7.2
46
2.7.3
Calculation
46
51
2.8.1
51
2.8.2
52
2.8.3
Calculation
52
57
2.9.1
57
2.9.2
58
2.9.3
Calculation
58
64
64
2.10.3 Calculation
65
70
70
71
2.11.3 Calculation
71
77
77
78
2.12.3 Calculation
78
82
82
83
2.13.3 Calculation
83
63
87
87
88
2.14.3 Calculation
88
Table of contents
92
92
93
2.15.3 Calculation
93
97
97
98
2.16.3 Calculation
98
103
105
107
108
2.17.3 Calculation
108
115
117
118
2.18.3 Calculation
118
123
124
124
2.19.3 Calculation
124
129
130
130
2.20.3 Calculation
130
135
135
136
2.21.3 Calculation
136
140
140
2.22.3 Calculation
140
Table of contents
143
143
143
2.23.3 Calculation
144
146
147
147
2.24.3 Calculation
147
152
154
2.25.2 FMEA
154
156
156
2.25.5 Calculation
156
162
164
2.26.2 FMEA
164
166
166
2.26.5 Calculation
166
3 Technical report TV Sd
172
4 Appendix
173
173
4.1.1
173
4.1.2
173
Foreword
1 Foreword
1.1 Notes on the manual
This description is only intended for the use of trained specialists in control and automation engineering
who are 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
requirements for safety, including all the relevant laws, regulations, guidelines and standards.
1.1.1
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development. For that reason the documentation is not in every case checked for consistency with
performance data, standards or other characteristics.
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
Trademarks
Beckhoff, TwinCAT, EtherCAT, Safety over EtherCAT, TwinSAFE and XFC are registered
trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
1.1.3
Patent Pending
The EtherCAT technology is patent protected, in particular by the following applications and patents:
EP1590927, EP1789857, DE102004044764, DE102007017835
with corresponding applications or registrations in various other countries.
The TwinCAT technology is patent protected, in particular by the following applications and patents:
EP0851348, US6167425 with corresponding applications or registrations in various other countries.
1.1.4
Copyright
Foreword
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
1.2.3
The Application Guide provides the user with examples for the calculation of safety parameters for safety
functions according to the standards DIN EN ISO 13849-1 and EN 62061 or EN 61508:2010
(if applicable), such as are typically used on machines.
In the examples an EL1904 is taken as an example for a safe input or an EL2904 for a safe output. This
is to be considered an example; of course other safe inputs or outputs can be used, such as an EP1908
or an EL2902. The appropriate parameters, which can be taken from the respective product
documentation, must then be used in the calculation.
Foreword
1.2.4
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
Failure to follow the safety instructions associated with this symbol directly endangers
the life and health of persons.
Caution - Risk of injury!
WARNING
Failure to follow the safety instructions associated with this symbol endangers the life
and health of persons.
Personal injuries!
CAUTION
Failure to follow the safety instructions associated with this symbol can lead to injuries
to persons.
Damage to the environment or devices
Attention
Failure to follow the instructions associated with this symbol can lead to damage to the
environment or equipment.
Tip or pointer
Note
1.2.5
Explanation of terms
Designation
Explanation
B10d
Mean number of cycles after 10% of the components have dangerously failed
CCF
dop
DCavg
hop
MTTFd
nop
PFH
PL
Performance Level
PLr
TZyklus
Mean time between two successive cycles of the system (given in minutes in the
following examples, but can also be given in seconds)
Foreword
1.6.1
1.6.0
1.5.0
1.4.0
1.3.1
1.3.0
1.2.0
1.1.0
Comment
Letter of conformity updated
Graphics in chapters 2.25 and 2.26 updated
Purpose and area of applications added
Chapters 2.25 and 2.26 added
Chapters 2.17 and 2.18 revised
Company address amended
Chapter 2.24 added
Documentation versions added
Document origin added
Formatting changed
Circuit examples
2 Circuit examples
2.1 ESTOP function variant 1 (Category 3, PL d)
The emergency stop button is connected via two normally closed contacts to an EL1904 safe input
terminal. The testing and the monitoring of the discrepancy of the two signals are activated. The restart
and the feedback signal are wired to standard terminals and are transferred to TwinSAFE via the
standard PLC. The contactors K1 and K2 are connected in parallel to the safe output. Current
measurement and testing of the output are active for this circuit.
K1
K2
Emergency stop
button
S1
Restart
S2
Logical connection in
the EL6900
K1
K2
2.1.1
EL1904
Parameter
Sensor test channel 1 active
Sensor test channel 2 active
Sensor test channel 3 active
Sensor test channel 4 active
Logic channel 1 and 2
Logic channel 3 and 4
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
Circuit examples
2.1.2
2.1.2.1
Block 1
K1
S1
EL1904
EL6900
EL2904
K2
2.1.3
Calculation
2.1.3.1
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
100,000
S2 B10d
10,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
2.1.3.2
Diagnostic Coverage DC
Component
Value
S1 with testing/plausibility
DCavg=99%
2.1.3.3
DCavg=90%
Calculation of the PFH and MTTFd values from the B10d values:
From:
and:
10
0,1
10
Circuit examples
K1/K2:
21,90
,
45662,1y
399999120h
21,90
1300000
0,1 21,90
593607,3y
5199997320h
1
produces for
0,1
S1:
1
10
1 0,99
45662,1 8760
1 DC
MTTF
2,50E
11
1 0,60
593607,3 8760
7,69E
11
1,92E
11
1 0,90
593607,3 8760
11
Circuit examples
Since the portion PFH K1 * PFH K2 *T1 is smaller than the rest by the power of ten, it is neglected
in this and all further calculations for the purpose of simplification.
to:
PFHges
2,50E11 1,11E09
3,42E09
1,03E09
1,25E09
as:
1
1
1
1
1904
1
6900
2904
with:
S1
10 1
0,1
K1
10
0,1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
EL6900
12
1
1
1904
1904
6900
6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
1,11E
1,03E
Circuit examples
EL2904
2904
2904
1
1,25E
MTTFd ges=
0,01
1,1E 05
913,2y
333,98
,
DCavg=
0,99
09 8760
%
,
%
,
%
,
%
,
%
,
%
,
%
,
98,96%
or:
%
DCavg=
%
,
98,99%
This structure is possible up to category 3 at the most, since an error in the feedback
path of the relays may be undiscovered. In order to attain category 3, all rising and
falling edges must be evaluated together with the time dependence in the controller for
the feedback expectation!
The restart lock is NOT part of the safety chain and must be implemented in the
machine!
13
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
14
Circuit examples
2.2.1
EL1904
Parameter
Sensor test channel 1 active
Sensor test channel 2 active
Sensor test channel 3 active
Sensor test channel 4 active
Logic channel 1 and 2
Logic channel 3 and 4
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
15
Circuit examples
2.2.2
2.2.2.1
Block 1
K1
S1
EL1904
EL6900
EL2904
K2
2.2.3
Calculation
2.2.3.1
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
100,000
S2 B10d
10,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
2.2.3.2
Diagnostic Coverage DC
Component
Value
DCavg=90%
DCavg=60%
DCavg=90%
2.2.3.3
Calculation of the PFH and MTTFd values from the B10d values:
From:
and:
16
Circuit examples
10
0,1
Inserting the values, this produces:
S1:
21,90
,
45662,1y
399999120h
K1/K2:
21,90
1300000
0,1 21,90
593607,3y
5199997320h
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,90
45662,1 8760
2,50E
10
1 0,60
593607,3 8760
7,69E
11
1,92E
11
1 0,90
593607,3 8760
17
Circuit examples
There is a coupling coefficient between the components that are connected via two channels. Examples
are temperature, EMC, voltage peaks or signals between these components. This is assumed to be the
worst-case estimation, where =10%. EN 62061 contains a table with which this -factor can be
precisely determined. Further, it is assumed that all usual measures have been taken to prevent both
channels failing unsafely at the same time due to an error (e.g. overcurrent through relay contacts,
overtemperature in the control cabinet).
This produces for the calculation of the PFH value for block 1:
PFH K2 /2
to:
PFHges
2,50E10
3,65E09
1,11E09
1,03E09
1,25E09
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
6900
2904
with:
18
S1
10 1
0,1
K1
10
0,1
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,03E
2904
2904
1,25E
MTTFd ges=
913,2y
333,98
,
DCavg=
0,99
09 8760
1,11E
6900
6900
EL2904
%
,
%
,
%
,
%
,
%
,
%
,
%
,
98,89%
or:
%
DCavg=
%
,
98,92%
The restart lock is NOT part of the safety chain and must be implemented in the
machine!
19
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
20
Circuit examples
2.3.1
EL1904
Parameter
Sensor test channel 1 active
Sensor test channel 2 active
Sensor test channel 3 active
Sensor test channel 4 active
Logic channel 1 and 2
Logic channel 3 and 4
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
21
Circuit examples
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
2.3.2
2.3.2.1
Block 1
K1
S1
EL1904
EL6900
EL2904
K2
2.3.3
Calculation
2.3.3.1
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
100,000
S2 B10d
10,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
2.3.3.2
Diagnostic Coverage DC
Component
Value
S1 with testing/plausibility
DCavg=99%
DCavg=90%
DCavg=99%
2.3.3.3
Calculation of the PFH and MTTFd values from the B10d values:
22
Circuit examples
From:
and:
10
0,1
21,90
,
45662,1y
399999120h
K1/K2:
21,90
1300000
0,1 21,90
593607,3y
5199997320h
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,99
45662,1 8760
2,50E
11
1 0,90
593607,3 8760
1,92E
11
1,92E
12
1 0,99
593607,3 8760
23
Circuit examples
PFH K2 /2
to:
PFHges
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
6900
2904
with:
24
S1
10 1
0,1
K1
10
0,1
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,03E
2904
2904
1,25E
MTTFd ges=
913,2y
333,98
,
DCavg=
0,99
09 8760
1,11E
6900
6900
EL2904
%
,
%
,
%
,
%
,
%
,
%
,
%
,
98,99%
or:
%
DCavg=
%
,
99,00%
This structure is possible up to category 4 at the most. In order to attain category 4, all
rising and falling edges must be evaluated together with the time dependence in the
controller for the feedback expectation!
The restart lock is NOT part of the safety chain and must be implemented in the
machine!
25
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
26
Circuit examples
2.4.1
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
27
Circuit examples
2.4.2
2.4.2.1
Block 1
K1
S1
EL1904
EL6900
EL2904
S2
EL1904
K2
2.4.3
Calculation
2.4.3.1
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
100,000
S2 B10d
10,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
2.4.3.2
Diagnostic Coverage DC
Component
Value
S1 with testing/plausibility
DCavg=99%
S2 with plausibility
DCavg=90%
DCavg=90%
DCavg=99%
2.4.3.3
Calculation of the PFH and MTTFd values from the B10d values:
From:
and:
28
Circuit examples
10
0,1
21,90
,
45662,1y
399999120h
S2:
21,90
4566210,0y
4E10h
K1/K2:
21,90
1300000
0,1 21,90
593607,3y
5199997320h
and the assumption that S1, S2, K1 and K2 are each single-channel:
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,99
45662,1 8760
2,50E
11
S2:
1 0,90
4566210,0 8760
2,50E
12
1 0,99
593607,3 8760
1,92E
12
29
Circuit examples
to:
PFHges
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
2
1
6900
2904
1904
with:
30
S1
10 1
0,1
S2
10 2
0,1
K1
10
0,1
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,11E
6900
6900
EL2904
1,03E
2904
2904
1,25E
MTTFd ges=
252,1
,
DCavgs=
913,2y
%
,
%
,
%
,
%
,
%
,
%
,
%
,
98,99%
or:
%
DCavgs=
%
,
%
,
%
,
%
,
99,0%
Category
Note
31
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
32
Circuit examples
2.5.1
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
No
Yes
33
Circuit examples
2.5.2
2.5.2.1
Block 1
K1
S1
EL1904
EL6900
EL2904
S2
EL1904
K2
2.5.3
Calculation
2.5.3.1
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
100,000
S2 B10d
10,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
2.5.3.2
Diagnostic Coverage DC
Component
Value
S1 with testing/plausibility
DCavg=99%
S2 with plausibility
DCavg=90%
DCavg=90%
DCavg=99%
2.5.3.3
Calculation of the PFH and MTTFd values from the B10d values:
From:
34
Circuit examples
and:
10
0,1
Inserting the values, this produces:
S1:
21,90
,
45662,1y
399999120h
S2:
21,90
4566210,0y
4E10h
K1/K2:
21,90
1300000
0,1 21,90
593607,3y
5199997320h
and the assumption that S1, S2, K1 and K2 are each single-channel:
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,99
45662,1 8760
2,50E
11
S2:
1 0,90
4566210,0 8760
2,50E
12
1 0,99
593607,3 8760
1,92E
12
35
Circuit examples
to:
PFHges
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
2
1
6900
2904
1904
with:
36
S1
10 1
0,1
S2
10 2
0,1
K1
10
0,1
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,11E
6900
6900
EL2904
1,03E
2904
2904
1,25E
MTTFd ges=
252,1
,
DCavgs=
913,2y
%
,
%
,
%
,
%
,
%
,
%
,
%
,
98,99%
or:
%
DCavgs=
%
,
%
,
%
,
%
,
99,0%
Category
Note
37
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
38
Circuit examples
Category
Note
2.6.1
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
39
Circuit examples
EL2904
Parameter
Current measurement active
Output test pulses active
Value
No
No
2.6.2
2.6.2.1
Block 1
K1
S1
EL1904
EL6900
EL2904
S2
EL1904
K2
2.6.3
Calculation
2.6.3.1
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
100,000
S2 B10d
10,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
2.6.3.2
Diagnostic Coverage DC
Component
Value
S1 with testing/plausibility
DCavg=99%
S2 with plausibility
DCavg=90%
DCavg=90%
40
Circuit examples
2.6.3.3
Calculation of the PFH and MTTFd values from the B10d values:
From:
and:
10
0,1
Inserting the values, this produces:
S1:
21,90
,
45662,1y
399999120h
S2:
K1/K2:
21,90
4566210,0y
4E10h
21,90
1300000
0,1 21,90
593607,3y
5199997320h
and the assumption that S1, S2, K1 and K2 are each single-channel:
1
produces for
0,1
S1:
S2:
1
10
1 0,99
45662,1 8760
1 0,90
4566210,0 8760
1 DC
MTTF
2,50E
2,50E
11
12
1 0,99
593607,3 8760
1,92E
12
41
Circuit examples
to:
PFHges
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
2
1
6900
2904
1904
with:
42
S1
10 1
0,1
S2
10 2
0,1
K1
10
0,1
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,11E
6900
6900
EL2904
1,03E
2904
2904
1,25E
MTTFd ges=
252,1
,
DCavgs=
913,2y
%
,
%
,
%
,
%
,
98,99%
43
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
44
Circuit examples
2.7.1
1. EL1904
Parameter
Sensor test channel 1 active
Sensor test channel 2 active
Sensor test channel 3 active
Sensor test channel 4 active
Logic channel 1 and 2
Logic channel 3 and 4
Value
Yes
not used
No
No
Single Logic
Single Logic
2. EL1904
Parameter
Sensor test channel 1 active
Sensor test channel 2 active
Sensor test channel 3 active
Sensor test channel 4 active
Logic channel 1 and 2
Logic channel 3 and 4
Value
not used
not used
Yes
not used
Single Logic
Single Logic
45
Circuit examples
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
2.7.2
2.7.2.1
Block 1
K1
S1
EL1904
EL6900
EL2904
S2
EL1904
K2
2.7.3
Calculation
2.7.3.1
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
100,000
S2 B10d
10,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
2.7.3.2
Diagnostic Coverage DC
Component
Value
S1 with plausibility
DCavg=90%
S2 with testing
DCavg=90%
DCavg=90%
DCavg=99%
46
Circuit examples
2.7.3.3
Calculation of the PFH and MTTFd values from the B10d values:
From:
and:
10
0,1
Inserting the values, this produces:
S1:
21,90
,
45662,1y
399999120h
S2:
21,90
4566210,0y
4E10h
K1/K2:
21,90
1300000
0,1 21,90
593607,3y
5199997320h
and the assumption that S1, S2, K1 and K2 are each single-channel:
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,90
45662,1 8760
2,50E
10
S2:
1 0,90
4566210,0 8760
2,50E
12
1 0,99
593607,3 8760
1,92E
12
47
Circuit examples
This produces for the calculation of the PFH value for block 1:
to:
PFHges
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
2
1
6900
2904
1904
with:
48
S1
10 1
0,1
S2
10 2
0,1
K1
10
0,1
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,11E
6900
6900
EL2904
1,03E
2904
2904
1,25E
MTTFd ges=
252,1
,
DCavgs=
913,2y
%
,
%
,
%
,
%
,
%
,
%
,
%
,
98,94%
or:
%
DCavgs=
%
,
%
,
%
,
%
,
98,95%
Category
Note
49
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
50
Circuit examples
2.8.1
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
51
Circuit examples
2.8.2
2.8.2.1
Block 1
S1
K1
EL1904
EL6900
EL2904
S2
K2
2.8.3
Calculation
2.8.3.1
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
1,000,000
S2 B10d
2,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
2.8.3.2
Diagnostic Coverage DC
Component
Value
DCavg=99%
DCavg=90%
2.8.3.3
Calculation of the PFH and MTTFd values from the B10d values:
From:
and:
10
0,1
52
Circuit examples
14720
679,3y
5951087h
S2:
14720
1358,7y
11902174h
K1/K2:
14720
1300000
0,1 14720
883,2y
7736413h
and the assumption that S1, S2, K1 and K2 are each single-channel:
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,99
679,3 8760
1,68E
1 0,99
1358,7 8760
8,4E
10
1 0,90
883,2 8760
1,29E
S2:
K1/K2:
53
Circuit examples
Relays K1 and K2 are both connected to the safety function. The non-functioning of a relay does not lead
to a dangerous situation, but it is discovered by the feedback. Furthermore, the B10d values for K1 and
K2 are identical.
There is a coupling coefficient between the components that are connected via two channels. Examples
are temperature, EMC, voltage peaks or signals between these components. This is assumed to be the
worst-case estimation, where =10%. EN 62061 contains a table with which this -factor can be
precisely determined. Further, it is assumed that all usual measures have been taken to prevent both
channels failing unsafely at the same time due to an error (e.g. overcurrent through relay contacts,
overtemperature in the control cabinet).
This produces for the calculation of the PFH value for block 1:
PFHges * PFH S1
* PFH K1
to:
PFHges
1,03E09
1,25E09
10% *
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
6900
2904
with:
54
S1
10 1
0,1
S2
10 2
0,1
K1
10
0,1
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,03E
2904
2904
1,25E
MTTFd ges=
913,2y
179,4
,
DCavg=
0,99
09 8760
1,11E
6900
6900
EL2904
%
,
%
,
%
,
%
,
%
,
%
,
%
,
96,26%
55
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
56
Circuit examples
2.9.1
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
57
Circuit examples
2.9.2
2.9.2.1
Block 1
S1
K1
EL1904
EL6900
EL2904
EL1904
S2
K2
2.9.3
Calculation
2.9.3.1
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
1,000,000
S2 B10d
2,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
2.9.3.2
Diagnostic Coverage DC
Component
Value
DCavg=99%
DCavg=99%
2.9.3.3
Calculation of the PFH and MTTFd values from the B10d values:
From:
and:
10
0,1
58
Circuit examples
14720
679,3y
5951087h
S2:
14720
1358,7y
11902174h
K1/K2:
14720
1300000
0,1 14720
883,2y
7736413h
and the assumption that S1, S2, K1 and K2 are each single-channel:
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,99
679,3 8760
1,68E
1 0,99
1358,7 8760
8,4E
10
1 0,99
883,2 8760
1,29E
09
S2:
K1/K2:
59
Circuit examples
PFHges
1,25E09
10%*
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
1904
1
6900
2904
with:
60
S1
10 1
0,1
S2
10 2
0,1
Circuit examples
10
0,1
K1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,03E
2904
2904
1,25E
MTTFd ges=
913,2y
152,7
,
DCavg=
0,99
09 8760
1,11E
6900
6900
EL2904
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
99,0%
Category
Note
61
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
62
Circuit examples
63
Circuit examples
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
Value
No
No
Yes
Yes
Single Logic
Single Logic
Value
Yes
Yes
S1
K1
EL1904
S2
EL6900
EL2904
K2
S3
EL1904
S4
64
Circuit examples
2.10.3 Calculation
2.10.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
1,000,000
S2 B10d
2,000,000
S3 B10d
20,000,000
S4 B10d
20,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
Value
DCavg=99%
DCavg=90%
DCavg=99%
and:
10
0,1
14720
679,3y
5951087h
65
Circuit examples
S2:
14720
1358,7y
11902174h
S3:
14720
13586,9y
119021739h
S4:
14720
13586,9y
119021739h
K1/K2:
21,90
1300000
0,1 21,90
883,2y
7736413h
and the assumption that S1, S2, S3, S4, K1 and K2 are each single-channel:
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,99
679,3 8760
1,68E
1 0,99
1358,7 8760
8,4E
10
S2:
S3/S4:
1 0,90
13586,9 8760
8,4E
10
K1/K2:
1 0,99
883,2 8760
66
1,29E
Circuit examples
* PFH S1
* PFH S3
to:
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
6900
2904
67
Circuit examples
with:
S1
10 1
0,1
S2
10 2
0,1
S3
10 3
0,1
S4
10 4
0,1
K1
10
0,1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
2904
2904
0,99
09 8760
0,01
1,1E 05
1,25E
913,2y
177,3
,
68
0,01
9,72E 06
1,03E
MTTFd ges=
DCavg=
0,99
09 8760
1,11E
6900
6900
EL2904
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
98,85%
Circuit examples
Category
Note
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
69
Circuit examples
70
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
Circuit examples
Value
Yes
Yes
EL1904
EL6900
Tumbler
S2
EL2904
Tumbler
UnLock
K1
EL2904
EL1904
Restart
K2
2.11.3 Calculation
2.11.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
2,000,000
S2 B10d
2,000,000
Restart - B10d
10,000,000
Lock B10d
100,000
Unlock B10d
100,000
K1 B10d
1,300,000
K2 B10d
1,300,000
Tumbler B10d
2,000,000
230
16
Lifetime (T1)
71
Circuit examples
Value
S1 with testing
DCavg=90%
DCavg=99%
DCavg=99%
Restart
DCavg=99%
DCavg=99%
Tumbler
DCavg=99%
and:
10
0,1
14720
1358,7y
11902174h
S2:
14720
1358,7y
11902174h
Lock/Unlock:
14720
67,9y
595108h
K1/K2:
21,90
1300000
0,1 21,90
72
883,2y
7736413h
Application Guide TwinSAFE
Circuit examples
Restart:
14720
6793,5y
59511060h
Tumbler:
14720
1358,7y
11902173h
and the assumption that S1, S2, S3, S4, K1, K2 and the tumbler are each single-channel:
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,90
1358,7 8760
8,40E
09
1 0,99
1358,7 8760
8,40E
10
S2:
Lock/Unlock:
1 0,99
67,9 8760
1,68E
08
Restart:
1 0,90
6793,5 8760
1,68E
09
K1/K2:
1 0,99
883,2 8760
1,29E
09
Tumbler:
1 0,99
1358,7 8760
8,40E
10
73
Circuit examples
* PFH Lock
PFH Unlock /2
to:
The MTTFd value for block 1 (based on the same assumption) is calculated with:
74
Circuit examples
as:
1
2|
|
1
6900
1
1904
1
|
2904|
1
2904
1
1904
with:
S1
10 1
0,1
S2
10 2
0,1
10
0,1
Lock
10
0,1
Unlock
10 4
0,1
Zuhaltung
K1
10
0,1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
EL6900
1904
1904
6900
6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
1,11E
1,03E
75
Circuit examples
EL2904
2904
2904
1
1,25E
S2|Lock|UNlock|EL2904|Zuhaltung
46,42
,
913,2y
57,82
MTTFd ges=
DCavg=
0,01
1,1E 05
0,99
09 8760
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
98,98%
Category
Note
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
76
Circuit examples
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
77
Circuit examples
S1
K1
EL1904
EL6900
EL2904
EL1904
S2
K2
2.12.3 Calculation
2.12.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
20,000,000
S2 B10d
20,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
Value
DCavg=99%
DCavg=99%
and:
10
0,1
78
Circuit examples
220800
905,8y
7934783h
K1/K2:
220800
1300000
0,1 220800
58,9y
515760h
and the assumption that S1, S2, K1 and K2 are each single-channel:
1
produces for
0,1
1
10
1 DC
MTTF
S1/S2:
1 0,99
905,8y 8760
1,26E
09
K1/K2:
1 0,99
58,9 8760
1,93E
79
Circuit examples
This produces for the calculation of the PFH value for block 1:
PFHges
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
1904
1
6900
2904
with:
S1
10 1
0,1
S2
10 2
0,1
K1
10
0,1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
EL6900
80
1904
1904
6900
6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
1,11E
1,03E
Circuit examples
EL2904
2904
2904
1
1,25E
MTTFd ges=
0,01
1,1E 05
913,2y
45,4
,
DCavg=
0,99
09 8760
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
99,0%
Category
Note
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
81
Circuit examples
Value
No
No
Yes
Yes
OSSD arbitrary types of pulse
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
82
Circuit examples
K1
Scanner
EL1904
EL6900
EL2904
K2
2.13.3 Calculation
2.13.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
7.67E-08
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
Value
DCavg=90%
DCavg=99%
and:
10
0,1
83
Circuit examples
22080
1300000
0,1 22080
588,7y
5157012h
1
produces for
0,1
1
10
1 DC
MTTF
K1/K2:
1 0,99
588,7 8760
1,94E
PFHges
84
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
2904
1
1904
6900
with:
10
0,1
K1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,01
9,72E 06
1028.8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,03E
2904
2904
1,25E
Scanner
1
7,67E
MTTFd ges=
0,90
08 8760
0,1
6,72E 04
913,2y
148,8y
87,8
,
DCavg=
0,99
09 8760
1,11E
6900
6900
EL2904
%
,
%
,
%
,
%
,
%
,
%
,
94,38%
85
Circuit examples
Category
Note
This structure is possible up to category 3 at the most through the use of the type 3
(category 3) laser scanner.
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
86
Circuit examples
Value
No
No
Yes
Yes
Asynchronous evaluation OSSD
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
87
Circuit examples
K1
Light
EL1904
curtain
EL6900
EL2904
K2
2.14.3 Calculation
2.14.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
1.50E-08
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
Value
DCavg=99%
DCavg=99%
and:
10
0,1
88
Circuit examples
44160
1300000
0,1 44160
294,4y
2578944h
1
produces for
0,1
1
10
1 DC
MTTF
K1/K2:
1 0,99
294,4 8760
3,88E
This produces for the calculation of the PFH value for block 1:
PFHges
89
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
2904
1
1904
6900
with:
10
0,1
K1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
1,25E
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,50E
913,2y
0,99
08 8760
76,1y
51,3
,
90
MTTFd ges=
1028.8y
0,01
1,31E 04
%
,
0,01
9,72E 06
1,03E
2904
2904
Lichtvorhang
DCavg=
0,99
09 8760
1,11E
6900
6900
EL2904
%
,
%
,
%
,
%
,
%
,
99,0%
Application Guide TwinSAFE
Circuit examples
Category
Note
This structure is possible up to category 4 at the most through the use of the type 4
(category 4) light curtain.
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
91
Circuit examples
Value
Yes
Yes
Yes
Yes
Cross-circuit is not a module error
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
92
Circuit examples
K1
Safety
EL1904
mat
EL6900
EL2904
K2
2.15.3 Calculation
2.15.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
6.00E06
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
Value
DCavg=99%
DCavg=99%
and:
10
0,1
93
Circuit examples
220800
1300000
0,1 220800
58,9y
515761h
Switching mat:
220800
6,00E06
0,1 220800
271,7y
2380434h
1
produces for
0,1
1
10
1 DC
MTTF
K1/K2:
1 0,99
58,9 8760
1,94E
08
Switching mat:
1 0,99
271,7 8760
4,20E
09
Circuit examples
to:
PFHges
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
2904
1904
6900
with:
10
0,1
K1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,01
9,72E 06
1028.8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,03E
2904
2904
1,25E
MTTFd ges=
913,2y
42,3
,
DCavg=
0,99
09 8760
1,11E
6900
6900
EL2904
%
,
%
,
%
,
%
,
%
,
%
,
99,0%
95
Circuit examples
Category
Note
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
96
Circuit examples
Value
No
No
Yes
Yes
Asynchronous evaluation OSSD
Single Logic
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
97
Circuit examples
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
K1
MS
K2
MS
Light
curtain
EL1904
EL6900
EL2904
MS
EL1904
S1
MS
2.16.3 Calculation
2.16.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
100,000
1.50E-08
MS1 B10d
100,000
MS2 B10d
100,000
MS3 B10d
100,000
MS4 B10d
100,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
Lifetime (T1)
98
Circuit examples
Value
DCavg=99%
DCavg=90%
DCavg=99%
S1 with testing
DCavg=90%
and:
10
0,1
1840
543,5y
4761060h
K1/K2:
1840
1300000
0,1 1840
7065,2
61891152h
543,5y
4761060h
MS1/MS2/MS3/S4:
1840
100000
0,1 1840
99
Circuit examples
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,90
543,5 8760
2,10E
K1/K2:
1 0,99
7065,2 8760
1,62E
10
MS1/MS2/MS3/S4:
1 0,90
543,5 8760
2,10E
PFHges
100
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
2904
1904
1
1904
6900
with:
K1
10
0,1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
EL6900
EL2904
1904
1904
6900
6900
Lichtvorhang
2904
2904
0,99
09 8760
0,01
9,72E 06
1028.8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,11E
1,03E
1,25E
0,01
1,31E 04
1
1,50E
913,2y
0,99
08 8760
76,1y
101
Circuit examples
MS1/MS3
1/ 3
1/ 3
0,90
8 8760
2,10E
543,6y
MTTFd ges=
44,0
,
%
,
DCavg=
0,1
1,84E 04
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
96,51%
Category
Note
This structure is possible up to category 4 at the most through the use of the type 4
(category 4) light curtain.
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
102
Circuit examples
The EL/KL9110 and EL/KL2xxx terminals used are not an active part of the safety
controller. Accordingly, the safety level attained is defined only through the higher-level
safety controller. The standard terminals are not incorporated in the calculation.
The external wiring of the standard terminals can lead to limitations in the maximum
attainable safety levels.
Prevention of feedback
Attention
103
Circuit examples
Open
K1
S1
Close
K2
S2
K1
K2
K3
K4
24V
0V
K1
I/O RUN
I/O ERR
BK9000
BECKHOFF
K2
K3
104
K4
Circuit examples
safedisconnection
(2channel,allpoles)
load
230V~
24V=
24V
0V
SELV/PELV
powersupply
potentialsupply
terminal
standard
terminal
Exceptions to the general requirement are allowed only if the manufacturer of the connected load
guarantees that feedback to the control input cannot occur.
2.17.1.2 Option 1: Ground feedback and all-pole disconnection (used in this example)
The ground connection of the connected load must be fed back to the safely switched ground of the
respective output terminal or potential group. (In this case: K1 correct wiring, K2 incorrect wiring)
safedisconnection
(2ch an nel,allp oles)
230V~
24V=
24V
0V
SELV/PELV
powersupply
K1
potentialsupply
terminal
K2
standard
terminal
105
Circuit examples
safedisconnection
(2ch an nel,onepole)
230V~
24V=
SELV/PELV
powersupply
24V
0V
potentialsu pply
terminal
Alternative1:
protectedcablerouting
K1
K2
standard
terminal
Alternative2:
Alternative3:
106
Circuit examples
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
107
Circuit examples
S1
K1
EL1904
EL6900
EL/KL2xxx
K3
...
EL2904
S2
K2
Nottakenintoaccount,
becau senonreactive
K4
2.17.3 Calculation
2.17.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
1,000,000
S2 B10d
2,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
K3 B10d
1,300,000
K4 B10d
1,300,000
230
Lifetime (T1)
Value
DCavg=99%
DCavg=99%
DCavg=90%
108
Circuit examples
and:
10
0,1
Inserting the values, this produces:
S1:
7360
1358,7y
11902212h
S2:
7360
2717,4y
23804424h
K1/K2/K3/K4:
7360
1300000
0,1 7360
1766,3y
15472788h
and the assumption that S1, S2, K1, K2, K3 and K4 are each single-channel:
produces for
0,1
S1:
1
10
1 0,99
1358,7 8760
1 DC
MTTF
8,40E
10
109
Circuit examples
S2:
K1/K2:
K3/K4:
1 0,99
2717,4 8760
4,20E
10
1 0,99
1766,3 8760
6,46E
10
1 0,90
1766,3 8760
6,46E
2
2
1904
6900
2904
4
2
to:
10%
10%
8,40
10
6,46
10
2
2
4,20
10
6,46
10
1,11
9 1,03
9 1,25
6,46
9 6,46
9
10%
2
9
4,1636
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
110
Circuit examples
1
1
1
1
1904
1
3
1
6900
2904
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,11E
6900
6900
EL2904
1,03E
2904
2904
1,25E
1
,
,
,
,
,
,
,
,
,
,
,
,
,
206,7
,
,
913,2y
,
,
0,9739
97,39%
,
,
111
Circuit examples
Category
Note
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
112
Circuit examples
The EL/KL9110 and EL/KL2xxx terminals used are not an active part of the safety
controller. Accordingly, the safety level attained is defined only through the higher-level
safety controller. The standard terminals are not incorporated in the calculation.
The external wiring of the standard terminals can lead to limitations in the maximum
attainable safety levels.
The standard terminals must be supplied with 24V by an SELV/PELV power supply
unit with an output voltage limit Umax of 60 V in the event of a fault.
Prevention of feedback
Attention
113
Circuit examples
Open
K1
S1
K2
S2
Close
Logical connection
in EL6900
K1
K2
K3
K4
24V
0V
K1
I/O RUN
I/O ERR
BK9000
BECKHOFF
K2
protected
cable routing
K3
114
K4
Circuit examples
safedisconnection
(2ch an nel,allp oles)
load
230V~
24V=
24V
0V
SELV/PELV
powersupply
potentialsu pply
terminal
standard
terminal
Exceptions to the general requirement are allowed only if the manufacturer of the connected load
guarantees that feedback to the control input cannot occur.
2.18.1.2 Option 1: Ground feedback and all-pole disconnection
The ground connection of the connected load must be fed back to the safely switched ground of the
respective output terminal or potential group. (In this case: K1 correct wiring, K2 incorrect wiring)
safedisconnection
(2chan nel,allp oles)
230V~
24V=
24V
0V
SELV/PELV
powersupply
K1
potentialsu pply
terminal
K2
standard
terminal
115
Circuit examples
2.18.1.3 Option 2: Cable short-circuit error exclusion (used here in the example)
If option 1 from chapter 2.18.1.2 is not feasible, the ground feedback and all-pole disconnection can be
dispensed with if the danger of feedback due to a cable short-circuit can be excluded by other measures.
The following measures can be implemented as an alternative.
safedisconnection
(2chan nel,onepole)
230V~
24V=
24V
0V
SELV/PELV
powersupply
potentialsupply
terminal
Alternative1:
protectedcablerouting
K1
K2
standard
terminal
Alternative2:
Alternative3:
CAUTION
116
The machine manufacturer or the user is solely responsible for the correct execution
and evaluation of the applied alternatives.
Circuit examples
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
117
Circuit examples
S1
K1
EL1904
EL6900
EL/KL2xxx
K3
...
EL2904
S2
K2
Nottakenintoaccount,
becau senonreactive
K4
2.18.3 Calculation
2.18.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
1,000,000
S2 B10d
2,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
K3 B10d
1,300,000
K4 B10d
1,300,000
230
Lifetime (T1)
Value
DCavg=99%
DCavg=99%
DCavg=90%
118
Circuit examples
and:
10
0,1
Inserting the values, this produces:
S1:
7360
1358,7y
11902212h
S2:
7360
2717,4y
23804424h
K1/K2/K3/K4:
7360
1300000
0,1 7360
1766,3y
15472788h
and the assumption that S1, S2, K1, K2, K3 and K4 are each single-channel:
produces for
0,1
S1:
1
10
1 0,99
1358,7 8760
1 DC
MTTF
8,40E
10
119
Circuit examples
S2:
K1/K2:
K3/K4:
1 0,99
2717,4 8760
4,20E
10
1 0,99
1766,3 8760
6,46E
10
1 0,90
1766,3 8760
6,46E
1
1
2
2
1904
6900
2904
4
2
to:
10%
10%
120
8,40
6,46
10
10
2
2
4,20
10
6,46
10
1,11
9 1,03
9 1,25
6,46
9 6,46
9
10%
2
9
4,1636
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1904
1
3
1
2904
6900
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
EL6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,11E
6900
6900
EL2904
1,03E
2904
2904
1,25E
1
,
913,2y
206,7
,
121
Circuit examples
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
0,9739
97,39%
Category
Note
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
*) In accordance with EN62061 chapter 6.7.7.2, SILCL in restricted to a maximum of SIL2 in relation to
structural constraints for a subsystem that has an HFT of 0 and for which fault exclusions have been
applied to faults that could lead to a dangerous failure.
122
Circuit examples
123
Circuit examples
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
K1
Safety over
S2
S1
EL1904
EL6900
EL2904
EtherCAT
K2
S1
EL1904
EL6900
2.19.3 Calculation
2.19.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
1.00E-09
S1 B10d
1,000,000
S2 B10d
2,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
Lifetime (T1)
124
Circuit examples
Value
S1 with testing/plausibility
DCavg=99%
S2 with plausibility
DCavg=90%
DCavg=99%
and:
10
0,1
7360
1358,7y
11902212h
S2:
7360
2717,4y
23804424h
K1/K2:
7360
1300000
0,1 7360
1766,3y
15472788h
and the assumption that S1, S2, K1 and K2 are each single-channel:
125
Circuit examples
produces for
0,1
S1:
S2:
1
10
1 DC
MTTF
1 0,99
1358,7 8760
8,40E
10
1 0,90
2717,4 8760
4,20E
09
1 0,99
1766,3 8760
6,46E
10
to:
PFHges
The MTTFd value for block 1 (based on the same assumption) is calculated with:
126
Circuit examples
as:
1
1
1
6900
1
1904
1
2
2904
1
6900
1904
with:
S1
10 1
0,1
S2
10 2
0,1
K1
10
0,1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
EL6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,11E
6900
6900
EL2904
1904
1904
1,03E
2904
2904
1,25E
1,00E
0,99
09 8760
913,2y
0,01
8,76E 06
1141,6y
MTTFd ges=
121,6
,
127
Circuit examples
DCavg=
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
98,62%
Category
Note
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
128
Circuit examples
129
Circuit examples
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
S1
EL1904
EL6900
AX5801
EL2904
AX5801
EL2904
AX5801
EL2904
AX5801
EL2904
AX5801
EL2904
AX5801
EL2904
AX5801
EL2904
AX5801
EL2904
EL2904
2.20.3 Calculation
2.20.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
AX5801 B10d
780,000
S1 B10d
100,000
230
Lifetime (T1)
130
Circuit examples
Value
S1 with testing/plausibility
DCavg=99%
AX5801
DCavg=99%
and:
10
0,1
1840
543,5y
4761060h
AX5801:
1840
780000
0,1 1840
4239,1y
37134516h
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,99
543,5 8760
2,10E
AX5801:
1 0,99
4239,1 8760
Application Guide TwinSAFE
2,70E
10
131
Circuit examples
PFHges
1,25E09
10%* 4*2,70E10
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1
1904
5801
1
5801
1
6900
2904
5801
5801
with:
S1
10 1
0,1
10
5801
0,1
AX5801
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
132
Circuit examples
Hence:
EL1904
1904
1904
EL6900
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,11E
6900
6900
EL2904
1,03E
2904
2904
1,25E
MTTFd ges=
173,8
,
DCavg=
913,2y
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
99,0%
Category
Note
The restart lock is NOT part of the safety chain and must be implemented in the
machine!
133
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
134
Circuit examples
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
135
Circuit examples
AX5805
Parameter
-
Value
S1
EL1904
EL6900
EL2904
AX5805
AX5805
AX5805
AX5805
S2
2.21.3 Calculation
2.21.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL6900 PFH
1.03E-09
AX5805 PFH
5.15E-09
S1 B10d
1,000,000
S2 B10d
2,000,000
230
Lifetime (T1)
Value
DCavg=99%
and:
10
0,1
136
Circuit examples
1840
5434,8y
47608848h
S2:
1840
10869,6y
95217696h
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,99
5434,8 8760
2,10E
10
S2:
1 0,99
10869,6 8760
1,05E
10
PFHges
137
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
5805
1904
1
6900
5805
5805
5805
with:
S1
10 1
0,1
S2
10 2
0,1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
EL6900
EL2904
AX5805
1904
1904
0,99
09 8760
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
0,99
09 8760
0,01
4,51E 05
1,11E
6900
6900
1,03E
2904
2904
1,25E
AX5805
AX5805
5,15E
MTTFd ges=
221,7y
49,8
,
138
913,2y
Circuit examples
DCavg=
%
,
%
,
%
,
%
,
%
,
%
,
%
,
%
,
99,0%
Category
Note
MTTFd
DCavg
Designation
none
low
medium
high
Cat
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
139
Circuit examples
Value
No
No
No
No
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
No
No
EL6900
EL2904
EL2904
EL1904
2.22.3 Calculation
2.22.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
230
Lifetime (T1)
140
Circuit examples
Value
EL1904/EL2904
DCavg=0%
as:
1
1904
2904
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
1,11E
1 0
09 8760
1
9,72E 06
1
1,25E
1 0
09 8760
102881y
1
EL2904
2904
2904
MTTFd ges=
1,1E
05
90909,1y
48262,6
,
DCavg=
%
,
0%
141
Circuit examples
Category
Note
MTTFd
DCavg
Designation
none
low
medium
high
Cat
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
142
Circuit examples
Value
No
No
No
No
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
No
No
EL6900
EL2904
EL2904
EL1904
EL2904
EL1904
143
Circuit examples
2.23.3 Calculation
2.23.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
230
Lifetime (T1)
Value
EL1904/EL2904
DCavg=90%
as:
1
1904
2904
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL1904
1904
1904
1 0,9
1,11E 09 8760
0,1
9,72E 06
10288,1y
144
Circuit examples
EL2904
2904
2904
MTTFd ges=
0,1
1,1E 05
9090,9y
4826,3
,
DCavg=
1 0,9
1,25E 09 8760
%
,
%
,
%
,
90%
Category
Note
MTTFd
DCavg
Designation
none
low
medium
high
Cat
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
145
Circuit examples
K1
K2
Not-Halt Taster
S1
Restart
S2
Logische Verbindung
in der EL6900
K1
K2
146
Circuit examples
Value
No
No
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
No
No
K1
S1
EL1904
EL6900
EL2904
K2
2.24.3 Calculation
2.24.3.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
S1 B10d
100,000
S2 B10d
10,000,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
147
Circuit examples
Value
S1 with plausibility
DCavg=90%
DCavg=90%
and:
10
0,1
Inserting the values, this produces:
S1:
21,90
,
45662,1y
399999120h
K1/K2:
21,90
1300000
0,1 21,90
593607,3y
5199997320h
1
produces for
0,1
1
10
1 DC
MTTF
S1:
1 0,90
45662,1 8760
2,50E
10
1 0,90
593607,3 8760
148
1,92E
11
Application Guide TwinSAFE
Circuit examples
to:
PFHges
The MTTFd value for block 1 (based on the same assumption) is calculated with:
as:
1
1
1
1
1904
1
6900
2904
with:
S1
10 1
0,1
45662,1y
K1
10
0,1
593607,3y
If only PFH values are available for EL1904, EL2904 and EL6900, the following estimation applies:
ELxxxx
149
Circuit examples
Hence:
EL1904
1904
1904
EL6900
0,01
9,72E 06
1028,8y
0,99
09 8760
0,01
9,02E 06
1108,6y
0,99
09 8760
0,01
1,1E 05
1,03E
2904
2904
1,25E
MTTFd ges=
913,2y
334,1
,
DCavgs=
0,99
09 8760
1,11E
6900
6900
EL2904
%
,
%
,
%
,
%
,
98,92%
Category
CAUTION
This structure is possible up to category 3 at the most. In order to attain category 3, all
rising and falling edges must be evaluated together with the time dependence in the
controller for the feedback expectation!
This is achieved via the implemented EDM function block.
150
The restart lock is NOT part of the safety chain and must be implemented in the
machine!
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
151
Circuit examples
K2
fieldbuse.g.PROFInet
STO
Speed
fieldbuse.g.EtherCAT
standardcommunication
Speed
EL6910
K1
K1
K2
Drive
Logicseebelow
SIL2communication
EL5021
positionvalue
Motor
152
Encoder
Sin/Cos1Vss
Circuit examples
EL5021
PC
BlackChannel
encodersignal
motorshaft
drive
EL6900
EL2904
actor
standardfieldbus
actualspeed
motorcable
Logic
SIL2Communication
Positionvalue
STODrive
StandardCommunication
Speed
x
y
Restart
EstopIn1
EstopIn2
STODrive
K1/K2
FeedbackK1/K2
500
1500
153
Circuit examples
2.25.2 FMEA
Error assumption
Speed value over PROFInet or
PROFInet itself freezes
154
Expectations
Detected via the second value and the plausibility check
in the EL6910 (other fieldbus and SIL2 communication
between EL5021 and EL6910).
In addition, the standard communication watchdog
should be activated for the speed 0.
Detected by the watchdog within the SIL2
communication.
Plausibility check: Dynamic speed values are also
expected when the motor is started.
A corrupt value within the SIL 2 communication results in
an invalid CRC inside the telegram and thus the
immediate cut-off of the group and the outputs
The data types of the two speed values have a different
length (e.g. 4 bytes and 11 bytes)
Detected via the second value and the plausibility check
in the EL6910 (other fieldbus and SIL2 communication
between EL5021 and EL6910).
Detected within the EL6910 via the plausibility check
with the speed value of the drive.
Plausibility check: Dynamic speed values are also
expected when the motor is started.
Detected within the EL6910 via the plausibility check
with the speed value of the drive
Detected via the second value and the plausibility check
in the EL6910 (other fieldbus and SIL2 communication
between EL5021 and EL6910).
Detected within the EL6910 via the plausibility check of
the speed values with the SIL2 communication
Checked
Circuit examples
Error assumption
Communication error 61784-3
for standard communication:
Loss
Communication error 61784-3
for standard communication:
Unacceptable delay
Communication error 61784-3
for standard communication:
Insertion
Communication error 61784-3
for standard communication:
Masquerading
Communication error 61784-3
for standard communication:
Addressing
Communication error for
standard communication:
Recurrent memory errors in
switches
Expectations
Detected within the EL6910 via the plausibility check of
the speed values with the SIL2 communication
Checked
155
Circuit examples
Value
Yes
Yes
Drive
K1
EL6910
Encoder
EL2904
EL5021
K2
2.25.5 Calculation
2.25.5.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
Drive MTBF
516,840 (59a)
Encoder MTTF
549,149
1,205,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
Value
DCavg=99%
156
Circuit examples
and:
10
0,1
Calculation of the PFH and MTTFd values from the MTBF values:
Note: Repair times can be neglected, therefore the following applies:
2
1
with
0,1
10
0,1
produces for
0,1
1
10
1 DC
MTTF
2
1 DC
MTTF
2 59
1 0,9
1.033.680
1.033.680
9,67E
118
08
Encoder:
2
1 DC
MTTF
2 549149
1 0,9
1.098.298
1.098.298
9,10E
125
08
EL5021:
2
1 DC
MTTF
2 1.205.000
1 0,9
2.410.000
4,15E
2.410.000
275
08
157
Circuit examples
K1/K2:
21,90
1300000
0,1 21,90
593607y
5.199.997.320h
1 0,99
593607,3 8760
1,92E
12
PFHges
as:
158
6900
1
5021
2904
1
Application Guide TwinSAFE
Circuit examples
with:
If only PFH values are available for EL1904, EL2904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL6900
6900
6900
EL2904
2904
2904
1,25E
0,99
09 8760
0,01
9,02E 06
0,99
09 8760
0,01
1,1E 05
1,03E
1108y
913y
45
0,02
0,022
90,9%
0,0219
0,022
99,5%
Category
CAUTION
Standstill
WARNING
When the motor is stopped, an error such as the freezing of an encoder signal is
detected only if a movement is requested. The machine manufacturer or user must
take this into account.
The restart lock is NOT part of the safety chain and must be implemented in the
machine!
159
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
DCavg
Name
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
160
Circuit examples
161
Circuit examples
24Vdc
PLC
K2
fieldbuse.g.PROFInet
STO
Speed
fieldbuse.g.EtherCAT
standardcommunication
speed
SIL2communication
speed
EL6224
IOLinkMaster
Drive
EL6910
K1
K1
K2
Logicseebelow
standardcommunication
speedoverIOlink
Motor
162
Encoder
Circuit examples
EL6224
PC
BlackChannel
speed
motorshaft
Drive
EL6900
EL2904
actor
standardfieldbus
actualspeed
motorcable
IO-link logic
SIL2Communication
Speed
STODrive
standardCommunication
Speed
x
y
Restart
EstopIn1
EstopIn2
STODrive
K1/K2
FeedbackK1/K2
500
1500
163
Circuit examples
2.26.2 FMEA
Error assumption
Speed value over PROFInet or
PROFInet itself freezes
164
Expectations
Detected via the second value and the plausibility check
in the EL6910 (SIL2 communication between EL6224
and EL6910)
In addition, the standard communication watchdog
should be activated for the speed 0.
Detected by the watchdog within the SIL2
communication.
Plausibility check: Dynamic speed values are also
expected when the motor is started.
A corrupt value within the SIL 2 communication results in
an invalid CRC inside the telegram and thus the
immediate cut-off of the group and the outputs
The data types of the two speed values have a different
length (e.g. 4 bytes and 11 bytes)
Detected via the second value and the plausibility check
in the EL6910 (SIL2 communication between EL6224
and EL6910)
Detected within the EL6910 via the plausibility check
with the speed value of the drive
Plausibility check: Dynamic speed values are also
expected when the motor is started.
Detected within the EL6910 via the plausibility check
with the speed value of the drive
Detected via the second value and the plausibility check
in the EL6910 (SIL2 communication between EL6224
and EL6910)
Detected within the EL6910 via the plausibility check of
the speed values with the SIL2 communication
Checked
Circuit examples
Error assumption
Communication error 61784-3
for standard communication:
Loss
Expectations
Detected within the EL6910 via the plausibility check of
the speed values with the SIL2 communication
Checked
165
Circuit examples
Value
Yes
Yes
Drive
K1
EL6910
Encoder
EL2904
EL6224
K2
2.26.5 Calculation
2.26.5.1 PFH / MTTFd /B10d values
Component
Value
EL1904 PFH
1.11E-09
EL2904 PFH
1.25E-09
EL6900 PFH
1.03E-09
Drive MTBF
516,840 (59y)
Encoder MTTF
1.208.880 (138y)
1,200,000
K1 B10d
1,300,000
K2 B10d
1,300,000
230
16
Lifetime (T1)
Value
DCavg=99%
166
Circuit examples
and:
10
0,1
Calculation of the PFH and MTTFd values from the MTBF values:
Note: Repair times can be neglected, therefore the following applies:
2
1
with
0,1
10
0,1
produces for
0,1
1
10
1 DC
MTTF
2
1 DC
MTTF
2 59
1 0,9
1.033.680
1.033.680
9,67E
118
08
Encoder:
2
1 DC
MTTF
2 549149
1 0,9
1.208.880
1.208.880
8,27E
138
08
EL6224:
2
1 DC
MTTF
2 1.200.000
1 0,9
2.400.000
4,17E
2.400.000
273
08
167
Circuit examples
K1/K2:
21,90
1300000
0,1 21,90
593607y
5.199.997.320h
1 0,99
593607,3 8760
1,92E
12
168
Circuit examples
as:
1
2904
6224
6900
with:
If only PFH values are available for EL1904, EL2904 and EL6900, the following estimation applies:
ELxxxx
Hence:
EL6900
6900
6900
EL2904
2904
2904
1,25E
0,99
09 8760
0,01
9,02E 06
0,99
09 8760
0,01
1,1E 05
1,03E
1108y
913y
46
0,0194
0,0214
90,65%
0,0212
0,0214
99,07%
Category
CAUTION
Standstill
WARNING
When the motor is stopped, an error such as the freezing of an encoder signal is
detected only if a movement is requested. The machine manufacturer or user must
take this into account.
Implement a restart lock in the machine!
CAUTION
The restart lock is NOT part of the safety chain and must be implemented in the
machine!
169
Circuit examples
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
For practical usability, the number of the ranges was limited to four. An accuracy of 5% is assumed for the limit
values shown in this table.
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
170
Circuit examples
171
Technical report TV Sd
3 Technical report TV Sd
172
Appendix
4 Appendix
4.1 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.
+ 49 (0) 5246/963-157
+ 49 (0) 5246/963-9157
support@beckhoff.com
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:
Fax:
E-mail:
+ 49 (0) 5246/963-460
+ 49 (0) 5246/963-479
service@beckhoff.com
173