TC3 TwinSAFE

TwinCAT 3

Software

10.01.2013

TC3 TwinSAFE

Safety and standard I/O in one system

10.01.2013

TC3 TwinSAFE

Safety and standard I/O in one system

1. High Performance Control

2. Scalable Hardware
3. One Software TwinCAT
4. Outstanding Diagnostics

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TC3 TwinSAFE

High Performance Control

High Performance expands possibilities

1 controller
50us PLC scan rate
30us I/O update rate
Synchronous Scan
10ns resolution w/
XFC Terminals
100 data point w/
Oversampling
Terminals
250us Motion task

11,000 Terminal Demo

4ms update rate
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TC3 TwinSAFE

Safety and standard I/O in one system

1. High Performance Control

2. Scalable Hardware
3. One Software TwinCAT
4. Outstanding Diagnostics

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TC3 TwinSAFE

Scalable Hardware
Scalable I/O including TwinSAFE works with any size system

1 Controller
1 EtherCAT NIC(built in)
0 switches
0 IP addresses
0 I/O configuration
Auto Scan
Software sends config info

Redundancy(Ring)
65,535 Devices

11,000 Terminal Demo

255 Axes
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TC3 TwinSAFE

Scalable Hardware
Scalable I/O works with any field bus protocol

25+ protocols
TwinSAFE Variables
can be tied to these
other systems

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TC3 TwinSAFE

Scalable Hardware
Scalable I/O does not require racks or backplane chassis

400+ Terminal Types

IP20, 65, 67, IP69K
100 Oversampling
Power Monitoring
LoadCell
AC/DC Motor
Stepper
Servo
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TC3 TwinSAFE

Scalable Hardware
Scalable Controllers work with all of the I/O Devices

266Mhz Atom CPU

2.1Ghz i7 Quad Core
Multi HD Raid
SSD
Cfast Flash
Fan/Fanless
Integrated PBs/LTs

All TwinSAFE ready

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TC3 TwinSAFE

Scalable Hardware
Scalable Motion

255 Axis
2 axis per drive
Single Cable
Power/Feeback
Linear
Synchronous
Stepper
All TwinSAFE ready

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TC3 TwinSAFE

Scalable Hardware
Scalable Safety: TwinSAFE System

IPC
TwinCAT Development
Software
TwinSAFE CPU Logic
Controller Terminal
TwinSAFE Input Terminal
TwinSAFE Output Terminal

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TC3 TwinSAFE

Scalable Hardware
Scalable Safety: TwinSAFE System

Certified to SIL 3 according to

IEC 61508, EN 954 Cat. 4 and
and DIN EN ISO 13849 PLe
Approvals: UL, CE, ATEX
Enables networks with up to
1,024 TwinSAFE devices
Safe Motion
The required functions are
configured via TwinCAT
Development software
All TwinSAFE data can be sent
to other Network Protocols
ie:Ethernet/IP
Complete Hardware/Software
diagnostics

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TC3 TwinSAFE

Scalable Hardware
Scalable Safety : TwinSAFE EL6900 CPU Logic Controller

Supports up to 128 TwinSAFE

terminals.
14 different Safety software
functions available. Can easily
be selected and linked.

Multiple TwinSAFE Controllers

can co-exist within a network
255 Function blocks total
32 Independant TwinSAFE
Groups
Dip switch on Terminal
required for certification 0-1023.
Diagnostic Lights:
Voltage
Temperature
Communication
Function Block
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TC3 TwinSAFE

Scalable Hardware
Scalable Safety: TwinSAFE Various Input Devices

Operation Mode:
Standstill monitoring 1
Standstill monitoring 2
Digital

Logic of Channels:
Single logic
OSSD signals (two channel)
asynchronous pulses,
inactive sensortest
OSSD signals (two channel)
any pulse repetition,
inactive sensortest
Cross-circuit detection
cause no module fault

Standstill
Monitoring

Light Curtains

Laser Scanners

Safety Mats

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TC3 TwinSAFE

Scalable Hardware
Scalable Safety : TwinSAFE Input Terminals

Fail-safe inputs
Supports sensor test, short
clock signal every 250hz.
Diagnostic Lights:
Voltage
Temperature
Sensor Test
Cross Wiring

Dip switches on Terminal required

for certification 0-65535

EL1904 4ch

EL1908 8ch

Dip switches on Terminal required

for certification 0-4095

EP1908 8ch (IP65)

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TC3 TwinSAFE

Scalable Hardware
Scalable Safety: TwinSAFE Various Outputs

Standard outputs active:

PLC output control is logically
AND connected with the safety
outputs. SafeState is always
ensured, has priority.

Standard and
Safe output

Current measurement active:

Setting allows use of a common
ground for the safety outputs.
Enable/Disable min/max checks
of current measurement.

Common
Ground wiring

Testing of outputs active:

Test pulses of the safety outputs
can be deactivated.

Solid State
Devices

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TC3 TwinSAFE

Scalable Hardware
Scalable Safety : TwinSAFE Output Terminals

Fail-safe Outputs
Switches 24 V DC actuators.
Switches off automatically
(fail stop) if a fault is detected
Diagnostic Lights:
Voltage
Temperature
Output Current
Cross Wiring

Dip switches on Terminal

required for certification 0-1023.

EL1904 4ch
0.5Amp

EL1902 2ch
2.3Amp

EL1901 1ch
10Amp

EL2964 1ch
3 simultaneously N.O. contacts
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TC3 TwinSAFE

Scalable Hardware
Scalable Safety : TwinSAFE AX5805 Safety Card
Meets requirements for:
PL e / SIL 3

Stop Functions:
STO: Safe Torque Off
SS1: Safe Stop 1 STO
SS2: Safe Stop 2 SOS
Limiting Functions:
SOS: Safe Operating Stop
SSM: Safe Speed Monitor
SLS: Safe Limited Speed
SLP: Safe Limited Position
SAR: Safe Acceleration
Range
SSR: Safe Speed Range
SMA: Safe Maximum
Acceleration
SMS: Safe Maximum Speed
SDI: Safe Direction

Main voltage remains connected

No additional wiring or
switching device required!
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TC3 TwinSAFE

Scalable Hardware
Scalable Safety: Fieldbus Gateway

IPC acts as built in

gateway to other
controllers on network.
Integrate TwinSAFE
data to EthernetIP via
shared memory map.
1 CIP connection for
many nodes of I/O.
IPC can also be
programmed with PLC
logic and motion logic.

IPC is generic E/IP slave

498 bytes Input data
498 bytes Output data

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TC3 TwinSAFE

Scalable Hardware
Scalable Safety: Fieldbus Gateway

Uplink/Downlink values
for Generic CIP
connection to AB is
auto calculated . These
are the values which
would be typed into the
RSLogix5000 side.
Input / Output Memory
map connection occurs
as Scheduled Class1
Connection.

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TC3 TwinSAFE

Scalable Hardware
Scalable Safety: Field bus Gateway

Input /Output Shared

Memory Map Data looks
just like any other I/O
Device
Add 2nd NIC or
multiplex to expand
data xfer.

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TC3 TwinSAFE

Safety and standard I/O in one system

1. High Performance Control

2. Scalable Hardware
3. One Software TwinCAT
4. Outstanding Diagnostics

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: Development Overview

1.

All Software
Elements in
One Location
(Safety)

2.

All Code Writing

in One Location

3.

All Parameters
in One Location

4.

All Code
feedback in one
location

2.

2.
3.

1.

4.
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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: Add Target TwinSAFE Controller Terminal

Add Target
TwinSAFE
Controller
Terminal

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: Attach to Target PLC Terminal Controller

User
Administration
can be
performed

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Function Blocks

EL6900 has 14
total pre-defined
FB available

Safety functions
can easily be
selected and
linked.

All FB can be
freely connected
and are
complemented
with operators
such as AND,
OR, etc.

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Function Blocks

8 EstopPB or 4
DualContact
EstopPB can be
connected to
each Estop FB

Each Estop can

be set for single
or dual contacts

External Device
Monitoring
Inputs for
ensuring
Contactor is
switching states

Use AND blocks

for more Estops.

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Function Blocks

Add variables to
each input and
output of the FB
2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Function Blocks

Configurable
Delay Time
2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Function Blocks

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Function Blocks

2.

External Device Monitoring

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Function Blocks

Raw Material
additions

Automatic Roll
Changes

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Function Blocks

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Function Blocks

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Function Blocks

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinSAFE: Add Function Blocks to Group1 Network

Point at the
SafeEstop
function block

Hold down the

left-click button

Drag the
safeEstop block
onto the code
writing area.

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: Create TwinSAFE Function Block Variables
1.

Click on the
Restart input
connection point

2.

In the properties
windows you
can alter the
properties or
parameters of
the In Port

3.

2.

1.
2.

Single or Two
Channel
operation
Discrepancy
time
Select input as
N.C or N.O
Assign Variable
Name

3.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: Connection between FBs

Click and hold

connection and
drag connection
to another FB
connection
point.

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: Create TwinSAFE Function Block Variables

Click on
Comment and
add a comment
to a FB

2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: Create TwinSAFE Function Block Variables
1.

Selecting
magnifying glass
icon will zoom in
on workspace

2.

Selecting
magnifying glass
icon will auto scale
workspace to fit all
FBs

3.

Selecting
magnifying glass
icon will zoom out
on workspace

4.

Selecting
and moving the
move icon will
show a zoomed in
popup window of
workspace

5.

CTRL and Mouse

Wheel zooms
in/out

2.

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TC3 TwinSAFE

One Software TwinCAT

Create TwinSAFE Function Block Variables

Example of
several FB on
one network.
2.

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Download Safety Project, Start Safety Project

Click Download
Icon
2.

Username:
Administrator
Serial Number:
nnnnnnnn

Password:
TwinSAFE

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TC3 TwinSAFE

One Software TwinCAT

TwinCAT: TwinSAFE Version History

Click Version
Icon
2.

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TC3 TwinSAFE

Safety and standard I/O in one system

1. High Performance Control

2. Scalable Hardware
3. One Software TwinCAT
4. Outstanding Diagnostics

10.01.2013

44

TC3 TwinSAFE

Outstanding Diagnostics
Diagnostics: Online Monitoring

Green indicates
Input is
High/True
2.

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TC3 TwinSAFE

Outstanding Diagnostics
Diagnostics: Online Monitoring

Online status is
shown as Green
when ON.
2.

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TC3 TwinSAFE

Outstanding Diagnostics
Diagnostics: Online Monitoring

Each channel of
the connection
can be mapped
back to variable
tag for use in
the PLC.

2.

Live online
update of a
TwinSAFE or
any input/output
is available

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TC3 TwinSAFE

Outstanding Diagnostics
Diagnostics: Variable Tags

TwinSAFE Group
and FB Variable
Tags available to
be aliased to
PLC project.

2.

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TC3 TwinSAFE

Outstanding Diagnostics
Diagnostics: Variable Tags

Estop FB
Variable Tags
available to be
aliased to PLC
project.

2.

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TC3 TwinSAFE

Outstanding Diagnostics
Diagnostics: Document

Right-click on
the Project
level of the
safety tree view
in the Solution
Explorer

2.

Add Extra
company
specific data as
needed, notice
logo file jpg file
attached in
example.

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TC3 TwinSAFE

Outstanding Diagnostics
Diagnostics: Document

Detailed information
about devices and
parameters

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TC3 TwinSAFE

Outstanding Diagnostics
Diagnostics: Demo

TC3 TwinSAFE Document

Demo
TC3 Diagnostics Runtime
Demo

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TC3 TwinSAFE

I/O Configuration
I/O Configuration: Demo

TC3 TwinSAFE
I/O Auto Configuration Demo

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TC3 TwinSAFE

Questions

Questions?

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