Application Guide Twin Safe en
Application Guide Twin Safe en
Application Guide Twin Safe en
TwinSAFE
Version: 1.3.1
Date:
2012-02-01
Table of contents
Table of contents
1 Foreword
1.1
1.2
1.1.1
Disclaimer
1.1.2
Trademarks
1.1.3
Patent Pending
1.1.4
Copyright
Safety instructions
1.2.1
Delivery state
1.2.2
1.2.3
1.2.4
Explanation of terms
2 Circuit examples
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.1.1
2.1.2
2.1.3
Calculation
13
2.2.1
13
2.2.2
14
2.2.3
Calculation
14
19
2.3.1
19
2.3.2
20
2.3.3
Calculation
20
25
2.4.1
25
2.4.2
26
2.4.3
Calculation
26
31
2.5.1
31
2.5.2
32
2.5.3
Calculation
32
37
2.6.1
37
2.6.2
38
2.6.3
Calculation
38
43
1
Table of contents
2.8
2.9
2.7.1
43
2.7.2
44
2.7.3
Calculation
44
49
2.8.1
49
2.8.2
50
2.8.3
Calculation
50
55
2.9.1
55
2.9.2
56
2.9.3
Calculation
56
62
62
2.10.3 Calculation
63
68
68
69
2.11.3 Calculation
69
75
75
76
2.12.3 Calculation
76
80
80
81
2.13.3 Calculation
81
85
85
86
2.14.3 Calculation
86
90
90
91
2.15.3 Calculation
91
61
95
95
96
2.16.3 Calculation
96
Table of contents
101
102
102
2.17.3 Calculation
102
107
108
109
2.18.3 Calculation
109
114
115
115
2.19.3 Calculation
115
120
121
121
2.20.3 Calculation
121
126
126
127
2.21.3 Calculation
127
131
131
2.22.3 Calculation
131
134
134
134
2.23.3 Calculation
135
3 Technical report TV Sd
137
4 Appendix
138
4.1
138
4.1.1
138
4.1.2
138
Foreword
1 Foreword
1.1 Notes on the manual
This description is only intended for the use of trained specialists in control and automation technology
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.
In the event that it contains technical or editorial errors, we retain the right to make alterations at any time
and without warning.
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 covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with corresponding applications
or registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent 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.
1.2.2
Foreword
1.2.3
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
Notice
1.2.4
Explanation of terms
Designation
Explanation
B10d
CCF
dop
DCavg
hop
MTTFd
nop
PFH
PL
Performance Level
PLr
Tcycle
Circuit examples
2 Circuit examples
2.1 ESTOP function variant 1 (Category 3, PL d)
The emergency stop button is connected via two break contacts to an EL1904 safe input terminal. The
testing and 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 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.
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%
DCavg=60%
DCavg=90%
2.1.3.3
Calculation of the PFH and MTTFd values from the B10d values:
From:
60
and:
10
0.1
Application Guide TwinSAFE
Circuit examples
230 16 60
21.90
10080
100000
45662.1y 399999120h
0.1 21.90
K1/K2:
230 16 60
21.90
10080
1300000
593607.3y 5199997320h
0.1 21.90
and the assumption that S1, K1 and K2 are in each case single-channel:
results in a
!"
S1:
!"
1 $ 0.99
2.50E $ 11
45662.1 8760
!"
1 $ 0.60
7.69E $ 11
593607.3 8760
!"
1 $ 0.90
1.92E $ 11
593607.3 8760
Circuit examples
This produces for the calculation of the PFH value for block 1:
3.42E3.42E-09
1
1
=<
=
;;
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(2904)
1
+
(
(D1))
with:
(S1) =
10 (A1)
0.1
(K1) =
10 (D1)
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
(ELxxxx) =
(1 $ %&(BCFFF))
!"(BCFFF)
Hence:
(EL1904) =
10
(1 $ 0.99)
G1 $ %&(BC1904)H
0.01
=
=
= 1028.8y
!"(BC1904)
1.11E $ 09 @I 8760 IJ 9.72E $ 06 @J
Application Guide TwinSAFE
Circuit examples
#EL6900'
#1 $ 0.99'
G1 $ %&#BC6900'H
0.01
1108.6y
!"#BC6900'
1.03E $ 09 @ 8760 IJ 9.02E $ 06 @J
I
#EL2904'
#1 $ 0.99'
G1 $ %&#BC2904'H
0.01
913.2y
!"#BC2904'
1.25E $ 09 @ 8760 IJ 1.1E $ 05 @J
I
MTTFd tot=
@
L
L
L
L
L
R
R
R
R
MNOOP.LQ LSPT.TQ LLST.OQ ULV.PQ NUVOSW.VQ
UU%
333.98X
UU%
UU%
UU%
OS%
OS%
R
R
R
R
LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
L
L
L
L
L
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
98.96%
UU%
UU%
UU%
UU%
US%
US%
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
L
L
L
L
L
L
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
98.99%
DCavg= MNOOP.L
L
or:
DCavg=
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!
MTTFd
Designation for each channel
low
medium
high
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
11
Circuit examples
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
12
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
13
Circuit examples
2.2.2
2.2.2.1
Block 1
K1
S1
EL1904
EL6900
EL6900
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:
60
and:
14
Circuit examples
10
0.1
230 16 60
21.90
10080
100000
45662.1y 399999120h
0.1 21.90
K1/K2:
230 16 60
21.90
10080
1300000
593607.3y 5199997320h
0.1 21.90
and the assumption that S1, K1 and K2 are in each case single-channel:
1
results in a
!"
S1:
!"
1 $ 0.90
2.50E $ 10
45662.1 8760
!"
1 $ 0.60
7.69E $ 11
593607.3 8760
!"
1 $ 0.90
1.92E $ 11
593607.3 8760
15
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(2904)
1
+
(
(D1))
with:
(S1) =
10 (A1)
0.1
(K1) =
10 (D1)
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
16
Circuit examples
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 I 8760 J 9.72E $ 06 @J
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
@
I
!"#BC6900'
1.03E $ 09 8760 J 9.02E $ 06 @J
I
#EL2904'
MTTFd tot=
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
!"#BC2904'
1.25E $ 09 @I 8760 IJ 1.1E $ 05 @J
@
L
L
L
L
L
R
R
R
R
MNOOP.LQ LSPT.TQ LLST.OQ ULV.PQ NUVOSW.VQ
US%
333.98X
UU%
UU%
UU%
OS%
OS%
R
R
R
R
LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
L
L
L
L
L
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
98.89%
US%
UU%
UU%
UU%
US%
US%
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
L
L
L
L
L
L
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
98.92%
DCavg= MNOOP.L
L
or:
DCavg=
The restart lock is NOT part of the safety chain and must be implemented in the
machine!
MTTFd
Designation for each channel
low
medium
high
17
Circuit examples
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
18
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
19
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:
20
Circuit examples
From:
60
and:
10
0.1
230 16 60
21.90
10080
100000
45662.1y 399999120h
0.1 21.90
K1/K2:
230 16 60
21.90
10080
1300000
593607.3y 5199997320h
0.1 21.90
and the assumption that S1, K1 and K2 are in each case single-channel:
1
results in a
!"
S1:
!"
1 $ 0.99
2.50E $ 11
45662.1 8760
!"
1 $ 0.90
1.92E $ 11
593607.3 8760
!"
1 $ 0.99
1.92E $ 12
593607.3 8760
21
Circuit examples
3.42E3.42E-09
3.42E3.42E-09
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(2904)
1
+
(
(D1))
with:
(S1) =
22
10 (A1)
0.1
Circuit examples
#K1'
10 #D1'
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 8760 J 9.72E $ 06 @J
I
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
@
I
!"#BC6900'
1.03E $ 09 I 8760 J 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
!"#BC2904'
1.25E $ 09 @I 8760 IJ 1.1E $ 05 @J
MTTFd tot=
@
L
L
L
L
L
R
R
R
R
MNOOP.LQ LSPT.TQ LLST.OQ ULV.PQ NUVOSW.VQ
UU%
333.98X
UU%
UU%
UU%
US%
US%
R
R
R
R
LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
L
L
L
L
L
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
98.99%
UU%
UU%
UU%
UU%
UU%
UU%
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
L
L
L
L
L
L
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V
99.00%
DCavg= MNOOP.L
L
or:
DCavg=
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!
23
Circuit examples
MTTFd
Designation for each channel
low
medium
high
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
24
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
25
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:
60
and:
26
Circuit examples
10
0.1
230 16 60
21.90
10080
100000
45662.1y 399999120h
0.1 21.90
S2:
230 16 60
21.90
10080
10000000
4566210.0y 4E10h
0.1 21.90
K1/K2:
230 16 60
21.90
10080
1300000
593607.3y 5199997320h
0.1 21.90
and the assumption that S1, S2, K1 and K2 are in each case single-channel:
1
results in a
!"
S1:
!"
1 $ 0.99
2.50E $ 11
45662.1 8760
S2:
!"
1 $ 0.90
2.50E $ 12
4566210.0 8760
!"
1 $ 0.99
1.92E $ 12
593607.3 8760
27
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(2904)
1
1
1
+
+
+
(
(D1))
(A2)
(BC1904)
with:
(S1) =
10 (A1)
0.1
(S2) =
10 (A2)
0.1
(K1) =
10 (D1)
0.1
28
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 I 8760 J 9.72E $ 06 @J
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
!"#BC6900'
1.03E $ 09 @I 8760 IJ 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 I 8760 J 1.1E $ 05 @J
MTTFd tot=
DCavgs=
@
L
L
L
L
L
L
L
R
R
R
R
R
R
MNOOP.LQ LSPT.TQ LLST.OQ ULV.PQ NUVOSW.VQ MNOOPLS.SQ LSPT.TQ
252.1X
UU%
UU%
UU%
UU%
US%
US%
US%
UU%
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
98.99%
UU%
UU%
UU%
UU%
UU%
UU%
US%
UU%
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
99.0%
or:
DCavgs=
Category
This structure is possible up to category 4 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
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.
29
Circuit examples
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
30
Circuit examples
2.5.1
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
Value
No
Yes
31
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
K1/K2 with testing and EDM (actuation 1x per
week and indirect feedback)
DCavg=90%
2.5.3.3
DCavg=90%
DCavg=99%
Calculation of the PFH and MTTFd values from the B10d values:
From:
60
and:
32
Circuit examples
10
0.1
230 16 60
21.90
10080
100000
45662.1y 399999120h
0.1 21.90
S2:
230 16 60
21.90
10080
10000000
4566210.0y 4E10h
0.1 21.90
K1/K2:
230 16 60
21.90
10080
1300000
593607.3y 5199997320h
0.1 21.90
and the assumption that S1, S2, K1 and K2 are each single-channel:
1
produces for
!"
S1:
!"
1 $ 0.99
2.50E $ 11
45662.1 8760
S2:
!"
1 $ 0.90
2.50E $ 12
4566210.0 8760
!"
1 $ 0.99
1.92E $ 12
593607.3 8760
33
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(2904)
1
1
1
+
+
+
(
(D1))
(A2)
(BC1904)
with:
(S1) =
10 (A1)
0.1
(S2) =
10 (A2)
0.1
(K1) =
10 (D1)
0.1
34
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
!"#BC1904'
1.11E $ 09 @ 8760 IJ 9.72E $ 06 @J
I
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
!"#BC6900'
1.03E $ 09 @ 8760 IJ 9.02E $ 06 @J
I
#EL2904'
MTTFd tot=
DCavgs=
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 I 8760 J 1.1E $ 05 @J
@
L
L
L
L
L
L
L
R
R
R
R
R
R
MNOOP.LQ LSPT.TQ LLST.OQ ULV.PQ NUVOSW.VQ MNOOPLS.SQ LSPT.TQ
UU%
UU%
UU%
UU%
US%
US%
US%
UU%
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
252.1X
98.99%
or:
UU%
UU%
UU%
UU%
UU%
UU%
US%
UU%
R
R
R
R
R
R
LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
L
L
L
L
L
L
L
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
DCavgs= MNOOP.L
L
99.0%
Category
This structure is possible up to category 4 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
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.
35
Circuit examples
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
36
Circuit examples
Category
Notice
2.6.1
This structure is possible for a maximum of category 3, due to a possible latent error.
The EL2904 terminal is only SIL2 in this example- therefore, the entire structure is only
SIL2.
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
37
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%
38
Circuit examples
2.6.3.3
Calculation of the PFH and MTTFd values from the B10d values:
From:
60
and:
10
0.1
230 16 60
21.90
10080
100000
45662.1y 399999120h
0.1 21.90
S2:
230 16 60
21.90
10080
10000000
4566210.0y 4E10h
0.1 21.90
K1/K2:
230 16 60
21.90
10080
1300000
593607.3y 5199997320h
0.1 21.90
and the assumption that S1, S2, K1 and K2 are in each case single-channel:
1
results in a
!"
S1:
!"
1 $ 0.99
2.50E $ 11
45662.1 8760
S2:
!"
1 $ 0.90
2.50E $ 12
4566210.0 8760
!"
1 $ 0.99
1.92E $ 12
593607.3 8760
39
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(2904)
1
1
1
+
+
+
(
(D1))
(A2)
(BC1904)
with:
(S1) =
10 (A1)
0.1
(S2) =
10 (A2)
0.1
(K1) =
10 (D1)
0.1
40
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 8760 J 9.72E $ 06 @J
I
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
!"#BC6900'
1.03E $ 09 @I 8760 IJ 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 I 8760 J 1.1E $ 05 @J
MTTFd tot=
@
L
L
L
L
L
L
L
R
R
R
R
R
R
MNOOP.LQ LSPT.TQ LLST.OQ ULV.PQ NUVOSW.VQ MNOOPLS.SQ LSPT.TQ
UU%
UU%
UU%
UU%
US%
US%
US%
UU%
R
R
R
R
R
R
LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
L
L
L
L
L
L
L
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
DCavgs= MNOOP.L
L
252.1X
98.99%
MTTFd
Designation for each channel
low
medium
high
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
41
Circuit examples
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
42
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
43
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 plausibility
DCavg=90%
DCavg=90%
DCavg=99%
44
Circuit examples
2.7.3.3
Calculation of the PFH and MTTFd values from the B10d values:
From:
60
and:
10
0.1
230 16 60
21.90
10080
100000
45662.1y 399999120h
0.1 21.90
S2:
230 16 60
21.90
10080
10000000
4566210.0y 4E10h
0.1 21.90
K1/K2:
230 16 60
21.90
10080
1300000
593607.3y 5199997320h
0.1 21.90
and the assumption that S1, S2, K1 and K2 are in each case single-channel:
1
results in a
!"
S1:
!"
1 $ 0.90
2.50E $ 10
45662.1 8760
S2:
!"
1 $ 0.90
2.50E $ 12
4566210.0 8760
!"
1 $ 0.99
1.92E $ 12
593607.3 8760
45
Circuit examples
This produces for the calculation of the PFH value for block 1:
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(2904)
1
1
1
+
+
+
(
(D1))
(A2)
(BC1904)
with:
(S1) =
10 (A1)
0.1
(S2) =
10 (A2)
0.1
(K1) =
10 (D1)
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
(ELxxxx) =
46
(1 $ %&(BCFFF))
!"(BCFFF)
Application Guide TwinSAFE
Circuit examples
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 8760 J 9.72E $ 06 @J
I
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
@
I
!"#BC6900'
1.03E $ 09 I 8760 J 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
!"#BC2904'
1.25E $ 09 @ 8760 IJ 1.1E $ 05 @J
I
MTTFd tot=
@
L
L
L
L
L
L
L
R
R
R
R
R
R
MNOOP.LQ LSPT.TQ LLST.OQ ULV.PQ NUVOSW.VQ MNOOPLS.SQ LSPT.TQ
US%
252.1X
UU%
UU%
UU%
US%
US%
US%
UU%
R
R
R
R
R
R
LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
L
L
L
L
L
L
L
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
98.94%
US%
UU%
UU%
UU%
UU%
UU%
US%
UU%
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
MNOOP.L LSPT.T LLST.O ULV.P NUVOSW.V NUVOSW.V MNOOPLS.S LSPT.T
98.95%
DCavgs= MNOOP.L
L
or:
DCavgs=
Category
This structure is possible up to category 4 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
90 % DC < 99 %
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.
47
Circuit examples
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
48
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
49
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:
60
and:
50
10
0.1
Circuit examples
230 16 60
14720
15
1000000
679.3y 5951087h
0.1 14720
S2:
230 16 60
14720
15
2000000
1358.7y 11902174h
0.1 14720
K1/K2:
230 16 60
14720
1
1300000
883.2y 7736413h
0.1 14720
and the assumption that S1, S2, K1 and K2 are in each case single-channel:
1
results in a
!"
S1:
!"
1 $ 0.99
1.68E $ 9
679.3 8760
S2:
!"
1 $ 0.99
8.4E $ 10
1358.7 8760
K1/K2:
!"
1 $ 0.90
1.29E $ 8
883.2 8760
51
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 signal. 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, over
temperature in the control cabinet).
This produces for the calculation of the PFH value for block 1:
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
=
;;
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(2904)
1
+
(
(D1))
with:
(S1) =
10 (A1)
0.1
(S2) =
10 (A2)
0.1
(K1) =
10 (D1)
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
(ELxxxx) =
52
(1 $ %&(BCFFF))
!"(BCFFF)
Application Guide TwinSAFE
Circuit examples
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
!"#BC1904'
1.11E $ 09 @ 8760 IJ 9.72E $ 06 @J
I
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
!"#BC6900'
1.03E $ 09 @ 8760 IJ 9.02E $ 06 @J
I
#EL2904'
MTTFd tot=
DCavg=
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 I 8760 J 1.1E $ 05 @J
@
L
L
L
L
L
R
R
R
R
OWU.VQ LSPT.TQ LLST.OQ ULV.PQ TTV.PQ
179.4X
UU%
UU%
UU%
UU%
UU% US% US%
R
R
R
R
R
R
OWU.V LVNT.W LSPT.T LLST.O ULV.P TTV.P TTV.P
L
L
L
L
L
L
L
R
R
R
R
R
R
OWU.V LVNT.W LSPT.T LLST.O ULV.P TTV.P TTV.P
96.26%
MTTFd
Designation for each channel
low
medium
high
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
53
Circuit examples
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
54
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
55
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:
60
and:
56
10
0.1
Circuit examples
230 16 60
14720
15
1000000
679.3y 5951087h
0.1 14720
S2:
230 16 60
14720
15
2000000
1358.7y 11902174h
0.1 14720
K1/K2:
230 16 60
14720
15
1300000
883.2y 7736413h
0.1 14720
and the assumption that S1, S2, K1 and K2 are in each case single-channel:
1
results in a
!"
S1:
!"
1 $ 0.99
1.68E $ 9
679.3 8760
S2:
!"
1 $ 0.99
8.4E $ 10
1358.7 8760
K1/K2:
!"
1 $ 0.99
1.29E $ 09
883.2 8760
57
Circuit examples
PFHtot= 10%* (1.68E-09+1.68E-09)/2 +1.11E-09 + 1.03E-09 + 1.25E-09 + 10%* (1.29E09+1.29E-09)/2 +1.11E-09 = 4.80E4.80E-09
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(2904)
1
1
+
+
(
(D1))
(BC1904)
with:
(S1) =
10 (A1)
0.1
(S2) =
10 (A2)
0.1
(K1) =
10 (D1)
0.1
58
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 8760 J 9.72E $ 06 @J
I
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
!"#BC6900'
1.03E $ 09 @I 8760 IJ 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
!"#BC2904'
1.25E $ 09 @I 8760 IJ 1.1E $ 05 @J
MTTFd tot=
UU%
@
L
L
L
L
L
L
R
R
R
R
R
OWU.VQ LSPT.TQ LLST.OQ ULV.PQ TTV.PQ LSPT.TQ
152.7X
UU%
UU%
UU%
UU% UU% UU%
UU%
R
R
R
R
R
R
LVNT.W LSPT.T LLST.O ULV.P TTV.P TTV.P LSPT.T
L
L
L
L
L
L
L
R
R
R
R
R
R
R
OWU.V LVNT.W LSPT.T LLST.O ULV.P TTV.P TTV.P LSPT.T
DCavg= OWU.V
L
99.0%
Category
This structure is possible up to category 4 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
DCavg
Designation
none
low
medium
high
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
59
Circuit examples
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
60
Circuit examples
61
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
62
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%
60
and:
10
0.1
230 16 60
14720
15
1000000
679.3y 5951087h
0.1 14720
63
Circuit examples
S2:
230 16 60
14720
15
2000000
1358.7y 11902174h
0.1 14720
S3:
230 16 60
14720
15
20000000
13586.9y 119021739h
0.1 14720
S4:
230 16 60
14720
15
20000000
13586.9y 119021739h
0.1 14720
K1/K2:
230 16 60
21.90
10080
1300000
883.2y 7736413h
0.1 21.90
and the assumption that S1, S2, S3, S4, K1 and K2 are in each case single-channel:
1
results in a
!"
S1:
!"
1 $ 0.99
1.68E $ 9
679.3 8760
S2:
!"
1 $ 0.99
8.4E $ 10
1358.7 8760
S3/S4:
!"
1 $ 0.90
8.4E $ 10
13586.9 8760
K1/K2:
!"
64
1 $ 0.99
1.29E $ 9
883.2 8760
Application Guide TwinSAFE
Circuit examples
to:
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(BC2904)
1
+
(
(D1))
65
Circuit examples
with:
#S1'
10 #A1'
0.1
#S2'
10 #A2'
0.1
#S3'
10 #A3'
0.1
#S4'
10 #A4'
0.1
#K1'
10 #D1'
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 8760 J 9.72E $ 06 @J
I
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
@
I
!"#BC6900'
1.03E $ 09 I 8760 J 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 I 8760 J 1.1E $ 05 @J
MTTFd tot=
UU%
@
L
L
L
L
L
R
R
R
R
OWU.VQ LSPT.TQ LLST.OQ ULV.PQ TVV.PQ
177.3X
UU%
US%
US%
UU%
UU%
UU%
UU% UU% UU%
R
R
R
R
R
R
R
R
LVNT.W LVNTO.U LVNTO.U LSPT.T LSPT.T LLST.O ULV.P TVV.P TVV.P
L
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
R
R
OWU.V LVNT.W LVNTO.U LVNTO.U LSPT.T LSPT.T LLST.O ULV.P TVV.P TVV.P
DCavg=OWU.V
L
66
98.85%
Circuit examples
Category
Notice
MTTFd
Designation for each channel
low
medium
high
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
67
Circuit examples
S1
K1
K2
Restart
CLOSED
S2
Logical connection in
the EL6900
K1
Lock
K2
Unlock
68
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
Circuit examples
Value
Yes
Yes
S1
EL1904
EL6900
Lock
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
Restart - B10d
2,000,000
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)
69
Circuit examples
Value
S1 with testing
DCavg=90%
DCavg=99%
DCavg=99%
Restart
DCavg=99%
DCavg=99%
Tumbler
DCavg=99%
60
and:
10
0.1
230 16 60
14720
15
2000000
1358.7y 11902174h
0.1 14720
S2:
230 16 60
14720
15
2000000
1358.7y 11902174h
0.1 14720
Lock/Unlock:
230 16 60
14720
15
100000
67.9y 595108h
0.1 14720
K1/K2:
230 16 60
21.90
10080
1300000
883.2y 7736413h
0.1 21.90
70
Circuit examples
Restart:
230 16 60
14720
15
10000000
6793.5y 59511060h
0.1 14720
Tumbler:
230 16 60
14720
15
2000000
1358.7y 11902173h
0.1 14720
and the assumption that S1, S2, S3, S4, K1, K2 and the tumbler are in each case single-channel:
1
results in a
!"
S1:
!"
1 $ 0.90
8.40E $ 09
1358.7 8760
S2:
!"
1 $ 0.99
8.40E $ 10
1358.7 8760
Lock/Unlock:
!"
1 $ 0.99
1.68E $ 08
67.9 8760
Restart:
!"
1 $ 0.90
1.68E $ 09
6793.5 8760
K1/K2:
!"
1 $ 0.99
1.29E $ 09
883.2 8760
Tumbler:
!"
1 $ 0.99
8.40E $ 10
1358.7 8760
71
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
=
+
;;
(A2|Cjkl|mnojkl|BC2904|pqrosqt)
(BC1904)
1
1
1
+
+
+
(BC6900)
(BC2904) (
(D1))
1
1
+
+
(
(BC1904)) (
(uvwsrxs))
72
Circuit examples
with:
#S1'
10 #A1'
0.1
#S2'
10 #A2'
0.1
#Lock'
10 #Cjkl'
0.1
#Unlock'
10 #mojkl'
0.1
#Tumbler'
#K1'
10 #A4'
0.1
10 #D1'
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 8760 J 9.72E $ 06 @J
I
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
@
I
!"#BC6900'
1.03E $ 09 I 8760 J 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
!"#BC2904'
1.25E $ 09 @I 8760 IJ 1.1E $ 05 @J
73
Circuit examples
#S2|Lock|UNlock|EL2904|Tumbler'
1
1
1
1
4
4
4
#A2'
#Cjkl'
#BC2904'
#
qyzovx'
1
57.82X
1
1
1
1
4 67.9X 4 913.2X 4
1358.7X
1358.7X
@
MTTFd tot=
UU%
L
L
L
L
L
L
R
R
R
R
R
NW.TPQ LSPT.TQ LLST.OQ ULV.PQ TTV.PQ OWUV.NQ
46.42X
DCavg= NW.TP
L
98.98%
Category
This structure is possible up to category 4 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
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
74
Circuit examples
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
75
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%
60
and:
76
10
0.1
Circuit examples
230 16 60
220800
1
20000000
905.8y 7934783h
0.1 220800
K1/K2:
230 16 60
220800
1
1300000
58.9y 515760h
0.1 220800
and the assumption that S1, S2, K1 and K2 are in each case single-channel:
1
results in a
!"
S1/S2:
!"
1 $ 0.99
1.26E $ 09
905.8y 8760
K1/K2:
!"
1 $ 0.99
1.93E $ 8
58.9 8760
77
Circuit examples
This produces for the calculation of the PFH value for block 1:
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(BC2904)
1
1
+
+
(
(D1))
(BC1904)
with:
(S1) =
10 (A1)
0.1
(S2) =
10 (A2)
0.1
(K1) =
10 (D1)
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
(ELxxxx) =
(1 $ %&(BCFFF))
!"(BCFFF)
Hence:
(EL1904) =
(1 $ 0.99)
G1 $ %&(BC1904)H
0.01
=
=
= 1028.8y
@
I
!"(BC1904)
1.11E $ 09 I 8760 J 9.72E $ 06 @J
(EL6900) =
(1 $ %&(BC6900))
(1 $ 0.99)
0.01
=
=
= 1108.6y
!"(BC6900)
1.03E $ 09 @I 8760 IJ 9.02E $ 06 @J
78
Circuit examples
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 8760 J 1.1E $ 05 @J
I
MTTFd tot=
DCavg=
@
L
L
L
L
L
L
R
R
R
R
R
USN.TQ LSPT.TQ LLST.OQ ULV.PQ NT.UQ LSPT.TQ
UU% UU%
UU%
UU%
UU% UU% UU% UU%
R
R
R
R
R
R
R
USN.T USN.T LSPT.T LLST.O ULV.P NT.U NT.U LSPT.T
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
USN.T USN.T LSPT.T LLST.O ULV.P NT.U NT.U LSPT.T
45.4X
99.0%
Category
This structure is possible up to category 4 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
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
79
Circuit examples
EL2904
Parameter
Current measurement active
Output test pulses active
80
Value
No
No
Yes
Yes
OSSD any pulse repetition
Single Logic
Value
Yes
Yes
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%
60
and:
10
0.1
81
Circuit examples
230 16 60
22080
10
1300000
588.7y 5157012h
0.1 22080
1
results in a
!"
K1/K2:
!"
1 $ 0.99
1.94E $ 9
588.7 8760
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
82
Circuit examples
as:
1
1
1
1
4
4
;;
#Akrvx'
#BC1904'
#BC6900'
1
1
4
4
#BC2904' #
#D1''
with:
#K1'
10 #D1'
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
!"#BC1904'
1.11E $ 09 @I 8760 IJ 9.72E $ 06 @J
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
@
I
!"#BC6900'
1.03E $ 09 I 8760 J 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 I 8760 J 1.1E $ 05 @J
#Scanner'
#1 $ 0.90'
G1 $ %&#Akrvx'H
0.1
148.8y
@
I
!"#Akrvx'
7.67E $ 08 I 8760 J 6.72E $ 04 @J
MTTFd tot=
DCavg=
@
L
L
L
L
L
R
R
R
R
LMT.TQ LSPT.TQ LLST.OQ ULV.PQ NTT.WQ
US%
UU%
UU%
UU% UU% UU%
R
R
R
R
R
LMT.T LSPT.T LLST.O ULV.P NTT.W NTT.W
L
L
L
L
L
L
R
R
R
R
R
LMT.T LSPT.T LLST.O ULV.P NTT.W NTT.W
87.8X
94.38%
Category
Notice
This structure is possible up to category 3 at the most through the use of the type 3
(category 3) laser scanner.
83
Circuit examples
MTTFd
Designation for each channel
low
medium
high
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
84
Circuit examples
K1
K2
OSSD 1
OSSD 2
K1
K2
Logical connection in
the EL6900
Value
No
No
Yes
Yes
OSSD asynchronous analysis
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
85
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%
60
and:
86
10
0.1
Circuit examples
230 16 60
44160
5
1300000
294.4y 2578944h
0.1 44160
1
results in a
!"
K1/K2:
!"
1 $ 0.99
3.88E $ 9
294.4 8760
This produces for the calculation of the PFH value for block 1:
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
87
Circuit examples
as:
1
1
1
1
4
4
;;
#C|ks}jxrt'
#BC1904'
#BC6900'
1
1
4
4
#BC2904' #
#D1''
with:
#K1'
10 #D1'
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
!"#BC1904'
1.11E $ 09 @I 8760 IJ 9.72E $ 06 @J
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
@
I
!"#BC6900'
1.03E $ 09 I 8760 J 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 I 8760 J 1.1E $ 05 @J
#Light curtain'
76.1y
MTTFd tot=
UU%
#1 $ 0.99'
G1 $ %&#C|ts kqxsr|'H
0.01
@
I
!"#C|ts kqxsr|'
1.50E $ 08 I 8760 J 1.31E $ 04 @J
L
L
L
L
L
R
R
R
R
WO.LQ LSPT.TQ LLST.OQ ULV.PQ PUM.MQ
UU%
UU%
UU% UU% UU%
R
R
R
R
LSPT.T LLST.O ULV.P NTT.W PUM.M
L
L
L
L
L
R
R
R
R
R
WO.L LSPT.T LLST.O ULV.P NTT.W PUM.M
DCavg= WO.L
L
88
51.3X
99.0%
Circuit examples
Category
Notice
This structure is possible up to category 4 at the most through the use of the type 4
(category 4) light curtain.
MTTFd
Designation for each channel
low
medium
high
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
89
Circuit examples
Value
Yes
Yes
Yes
Yes
Short cut is no module fault
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
90
Circuit examples
K1
Safety
EL1904
bumper
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%
60
and:
10
0.1
91
Circuit examples
230 16 60
220800
1
1300000
58.9y 515761h
0.1 220800
Switching mat:
230 16 60
220800
1
6.00E06
271.7y 2380434h
0.1 220800
1
results in a
!"
K1/K2:
!"
1 $ 0.99
1.94E $ 08
58.9 8760
Switching mat:
!"
1 $ 0.99
4.20E $ 09
271.7 8760
92
Circuit examples
to:
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
=
+
+
;;
(A|sk|t yrs)
(BC1904)
(BC6900)
1
1
+
+
(BC2904) (
(D1))
with:
(K1) =
10 (D1)
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
(ELxxxx) =
(1 $ %&(BCFFF))
!"(BCFFF)
Hence:
(EL1904) =
(1 $ 0.99)
G1 $ %&(BC1904)H
0.01
=
=
= 1028.8y
@
I
!"(BC1904)
1.11E $ 09 I 8760 J 9.72E $ 06 @J
(EL6900) =
(1 $ %&(BC6900))
(1 $ 0.99)
0.01
=
=
= 1108.6y
@
I
!"(BC6900)
1.03E $ 09 I 8760 J 9.02E $ 06 @J
(EL2904) =
(1 $ %&(BC2904))
(1 $ 0.99)
0.01
=
=
= 913.2y
!"(BC2904)
1.25E $ 09 @I 8760 IJ 1.1E $ 05 @J
@
MTTFd tot=
UU%
L
L
L
L
L
R
R
R
R
PWL.WQ LSPT.TQ LLST.OQ ULV.PQ NT.UQ
UU%
UU%
UU% UU% UU%
R
R
R
R
LSPT.T LLST.O ULV.P NT.U NT.U
L
L
L
L
L
R
R
R
R
R
PWL.W LSPT.T LLST.O ULV.P NT.U NT.U
DCavg= PWL.W
L
= 42.3X
= 99.0%
93
Circuit examples
Category
Category 4 is attainable due to the structure of the circuit.
Notice
MTTFd
Designation for each channel
low
medium
high
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
94
Circuit examples
Value
No
No
Yes
Yes
OSSD asynchronous analysis
Single Logic
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
95
Circuit examples
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
K1
MS
K2
MS
Lightcurtain
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)
96
Circuit examples
Value
DCavg=99%
DCavg=90%
DCavg=99%
S1 with testing
DCavg=90%
60
and:
10
0.1
230 8 60
1840
60
100000
543.5y 4761060h
0.1 1840
K1/K2:
230 8 60
1840
60
1300000
7065.2 61891152h
0.1 1840
MS1/MS2/MS3/S4:
230 8 60
1840
60
100000
543.5y 4761060h
0.1 1840
and the assumption that S1, K1 and K2 are in each case single-channel:
1
97
Circuit examples
results in a
!"
S1:
!"
1 $ 0.90
2.10E $ 8
543.5 8760
K1/K2:
!"
1 $ 0.99
1.62E $ 10
7065.2 8760
MS1/MS2/MS3/S4:
!"
1 $ 0.90
2.10E $ 8
543.5 8760
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
98
Circuit examples
as:
1
1
1
1
4
4
;;
#C|ts kqxsr|'
#BC1904'
#BC6900'
1
1
1
1
4
4
4
4
#BC2904' #
#D1'' #
#A1'' #
#A3''
1
1
4
4
#BC1904'
#A1'
with:
#K1'
10 #D1'
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 I 8760 J 9.72E $ 06 @J
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
!"#BC6900'
1.03E $ 09 @ 8760 IJ 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
!"#BC2904'
1.25E $ 09 @I 8760 IJ 1.1E $ 05 @J
#Light curtain'
76.1y
#MS1/MS3'
#1 $ 0.99'
G1 $ %&#C|ts kqxsr|'H
0.01
!"#C|ts kqxsr|'
1.50E $ 08 @I 8760 IJ 1.31E $ 04 @J
#1 $ 0.90'
G1 $ %&#A1/A3'H
0.1
!"#A1/A3'
2.10E $ 8 @I 8760 IJ 1.84E $ 04 @J
543.6y
MTTFd tot=
@
L
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
R
WO.LQ LSPT.TQ LLST.OQ ULV.PQ WSON.PQ NMV.OQ NMV.OQ LSPT.TQ NMV.NQ
44.0X
99
Circuit examples
UU%
UU%
UU%
UU%
UU%
UU%
US% US% US% US%
UU%
UU%
R
R
R
R
R
R
R
R
R
R
LSPT.T LLST.O ULV.P WSON.P WSON.P NMV.O NMV.O NMV.O NMV.O LSPT.T NMV.N
L
L
L
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
R
R
R
R
WO.L LSPT.T LLST.O ULV.P WSON.P WSON.P NMV.O NMV.O NMV.O NMV.O LSPT.T NMV.N
DCavg= WO.L
L
96.51%
Category
Notice
This structure is possible up to category 4 at the most through the use of the type 4
(category 4) light curtain.
MTTFd
Designation for each channel
low
medium
high
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
100
Circuit examples
The safety consideration ends at K1/K2. The EL/KL9110 and EL/KL2xxx terminals
used are not taken into account for the calculation.
I/O RUN
BK9000
BECKHOFF
I/O ERR
101
Circuit examples
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
S1
K1
EL1904
EL6900
EL2904
EL1904
S2
K2
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
230
Lifetime (T1)
102
Circuit examples
Value
DCavg=99%
DCavg=99%
60
and:
10
0.1
230 8 60
7360
15
1000000
1358.7y 11902212h
0.1 7360
S2:
230 8 60
7360
15
2000000
2717.4y 23804424h
0.1 7360
K1/K2:
230 8 60
7360
15
1300000
1766.3y 15472788h
0.1 7360
and the assumption that S1, S2, K1 and K2 are in each case single-channel:
1
results in a
!"
103
Circuit examples
S1:
!"
1 $ 0.99
8.40E $ 10
1358.7 8760
S2:
!"
1 $ 0.99
4.20E $ 10
2717.4 8760
K1/K2:
!"
1 $ 0.99
6.46E $ 10
1766.3 8760
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
104
Circuit examples
as:
1
1
1
1
1
4
4
4
;;
#A1'
#BC1904'
#BC6900'
#2904'
1
1
4
4
#
#D1''
#BC1904'
with:
#S1'
10 #A1'
0.1
#S2'
10 #A2'
0.1
#K1'
10 #D1'
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 8760 J 9.72E $ 06 @J
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
@
I
!"#BC6900'
1.03E $ 09 I 8760 J 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 I 8760 J 1.1E $ 05 @J
MTTFd tot=
UU%
@
L
L
L
L
L
L
R
R
R
R
R
LVNT.WQ LSPT.TQ LLST.OQ ULV.PQ LWOO.VQ LSPT.TQ
190.7X
UU%
UU%
UU%
UU%
UU%
UU%
UU%
R
R
R
R
R
R
PWLW.M LSPT.T LLST.O ULV.P LWOO.V LWOO.V LSPT.T
L
L
L
L
L
L
L
R
R
R
R
R
R
R
LVNT.W PWLW.M LSPT.T LLST.O ULV.P LWOO.V LWOO.V LSPT.T
DCavg= LVNT.W
L
99.0%
105
Circuit examples
Category
This structure is possible up to category 4 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
DCavg
Designation
none
low
medium
high
Category
Range
DC < 60 %
60 % DC < 90 %
60 % DC < 90 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
106
Circuit examples
The 24 V supply voltage must never be applied to an output of a digital output terminal!
This wiring error is not reliably detected by the system.
Cross-circuits between the outputs of different digital output terminals must be avoided
at all costs. These are not detected by the system.
In accordance with DIN EN ISO 13849-2, the following measures are necessary for the
assumption of the error exclusion external voltage:
Safety consideration
Notice
The safety consideration ends at K1/K2. The EL/KL9110 and EL/KL2xxx terminals
used are not taken into account for the calculation.
107
Circuit examples
I/O RUN
BK9000
BECKHOFF
I/O ERR
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
Yes
Yes
108
Circuit examples
2.18.2
2.18.2.1 Block 1
S1
K1
EL1904
EL6900
EL2904
EL1904
S2
K2
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
230
Lifetime (T1)
Value
DCavg=99%
DCavg=99%
60
and:
10
0.1
109
Circuit examples
230 8 60
7360
15
1000000
1358.7y 11902174h
0.1 7360
S2:
230 8 60
7360
15
2000000
2717.4y 23804424h
0.1 7360
K1/K2:
230 8 60
7360
15
1300000
1766.3y 15472788h
0.1 7360
and the assumption that S1, S2, K1 and K2 are in each case single-channel:
1
results in a
!"
S1:
!"
1 $ 0.99
8.40E $ 10
1358.7 8760
S2:
!"
1 $ 0.99
4.20E $ 10
2717.4 8760
K1/K2:
!"
110
1 $ 0.99
6.46E $ 10
1766.3 8760
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(2904)
1
1
+
+
(
(D1))
(BC1904)
with:
(S1) =
10 (A1)
0.1
(S2) =
10 (A2)
0.1
(K1) =
10 (D1)
0.1
111
Circuit examples
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 8760 J 9.72E $ 06 @J
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
!"#BC6900'
1.03E $ 09 @I 8760 IJ 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 I 8760 J 1.1E $ 05 @J
MTTFd tot=
UU%
@
L
L
L
L
L
L
R
R
R
R
R
LVNT.WQ LSPT.TQ LLST.OQ ULV.PQ LWOO.VQ LSPT.TQ
190.7X
UU%
UU%
UU%
UU%
UU%
UU%
UU%
R
R
R
R
R
R
PWLW.M LSPT.T LLST.O ULV.P LWOO.V LWOO.V LSPT.T
L
L
L
L
L
L
L
R
R
R
R
R
R
R
LVNT.W PWLW.M LSPT.T LLST.O ULV.P LWOO.V LWOO.V LSPT.T
DCavg= LVNT.W
L
99.0%
Category
This structure is possible up to category 4 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
DCavg
Designation
none
low
medium
high
112
Range
DC < 60 %
90 % DC < 99 %
90 % DC < 99 %
99 % DC
Circuit examples
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
113
Circuit examples
RT Ethernet or Wireless
Ethernet
114
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)
115
Circuit examples
Value
S1 with testing/plausibility
DCavg=99%
S2 with plausibility
DCavg=90%
DCavg=99%
60
and:
10
0.1
230 8 60
7360
15
1000000
1358.7y 11902212h
0.1 7360
S2:
230 8 60
7360
15
2000000
2717.4y 23804424h
0.1 7360
K1/K2:
230 8 60
7360
15
1300000
1766.3y 15472788h
0.1 7360
and the assumption that S1, S2, K1 and K2 are in each case single-channel:
116
1
Circuit examples
results in a
!"
S1:
!"
1 $ 0.99
8.40E $ 10
1358.7 8760
S2:
!"
1 $ 0.90
4.20E $ 09
2717.4 8760
!"
1 $ 0.99
6.46E $ 10
1766.3 8760
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
117
Circuit examples
as:
1
1
1
1
1
4
4
4
;;
#A1' #
#D1''
#A2'
#BC1904'
1
1
1
1
4
4
4
4
#BC6900'
#2904'
#A1'
#A $ j $ B'
1
1
4
4
#BC1904'
#BC6900'
with:
#S1'
10 #A1'
0.1
#S2'
10 #A2'
0.1
#K1'
10 #D1'
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
!"#BC1904'
1.11E $ 09 @I 8760 IJ 9.72E $ 06 @J
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
!"#BC6900'
1.03E $ 09 @I 8760 IJ 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
@
I
!"#BC2904'
1.25E $ 09 I 8760 J 1.1E $ 05 @J
#S $ o $ E'
#1 $ %&#A $ j $ B''
#1 $ 0.99'
0.01
@
I
!"#A $ j $ B'
1.00E $ 09 I 8760 J 8.76E $ 06 @J
1141.6y
MTTFd tot=
118
@
L
L
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
R
R
LVNT.W LWOO.V PWLW.MQ LSPT.TQ LLST.OQ ULV.PQ LVNT.WQ LSPT.TQ LSPT.TQ LLST.OQ
121.6X
Circuit examples
UU%
UU%
UU%
US%
UU%
UU%
UU%
UU%
UU%
UU%
UU%
R
R
R
R
R
R
R
R
R
LWOO.V LWOO.V PWLW.M LSPT.T LLST.O ULV.P LVNT.W LSPT.T LSPT.T LLST.O
L
L
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
R
R
R
LVNT.W LWOO.V LWOO.V PWLW.M LSPT.T LLST.O ULV.P LVNT.W LSPT.T LSPT.T LLST.O
DCavg= LVNT.W
L
98.62%
Category
This structure is possible up to category 4 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
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
119
Circuit examples
120
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)
121
Circuit examples
Value
S1 with testing/plausibility
DCavg=99%
AX5801
DCavg=99%
60
and:
10
0.1
230 8 60
1840
60
100000
543.5y 4761060h
0.1 1840
AX5801:
230 8 60
1840
60
780000
4239.1y 37134516h
0.1 1840
1
results in a
!"
S1:
!"
1 $ 0.99
2.10E $ 9
543.5 8760
AX5801:
!"
122
1 $ 0.99
2.70E $ 10
4239.1 8760
Application Guide TwinSAFE
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
=<
;;
=
>?@
as:
1
1
1
1
1
=
+
+
+
;;
(A1)
(BC1904)
(BC6900)
(BC2904)
1
1
1
+
+
+
(5801)
(5801)
(5801)
1
+
(5801)
with:
(S1) =
10 (A1)
0.1
(AX5801) =
10 (5801)
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
(ELxxxx)
(1 $ %&(BCFFF))
!"(BCFFF)
123
Circuit examples
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 8760 J 9.72E $ 06 @J
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
@
I
!"#BC6900'
1.03E $ 09 I 8760 J 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
!"#BC2904'
1.25E $ 09 @ 8760 IJ 1.1E $ 05 @J
MTTFd tot=
@
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
NMV.NQ LSPT.TQ LLST.OQ ULV.PQ MPVU.LQ MPVU.LQ MPVU.LQ MPVU.LQ
173.8X
UU%
UU%
UU%
UU%
UU%
UU%
UU%
UU%
UU%
UU%
UU%
UU%
R
R
R
R
R
R
R
R
R
R
R
NMV.N LSPT.T LLST.O ULV.P MPVU.L MPVU.L MPVU.L MPVU.L MPVU.L MPVU.L MPVU.L MPVU.L
L
L
L
L
L
L
L
L
L
L
L
L
R
R
R
R
R
R
R
R
R
R
R
NMV.N LSPT.T LLST.O ULV.P MPVU.L MPVU.L MPVU.L MPVU.L MPVU.L MPVU.L MPVU.L MPVU.L
DCavg=
99.0%
Category
This structure is possible up to category 4 at the most.
Notice
The restart lock is NOT part of the safety chain and must be implemented in the
machine!
MTTFd
Designation for each channel
low
medium
high
DCavg
Designation
none
low
medium
high
124
Range
DC < 60 %
60 % DC < 90 %
90 % DC < 99 %
99 % DC
Circuit examples
Category
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
125
Circuit examples
Logical connection in
the EL6900
OPEN
S1
S2
CLOSED
AX5805
AX5000
AX5805
AX5000
AX5805
AX5000
AX5805
AX5000
126
Value
Yes
Yes
Yes
Yes
Single Logic
Single Logic
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%
60
and:
10
0.1
127
Circuit examples
230 8 60
1840
60
1000000
5434.8y 47608848h
0.1 1840
S2:
230 8 60
1840
60
2000000
10869.6y 95217696h
0.1 1840
1
results in a
!"
S1:
!"
1 $ 0.99
2.10E $ 10
5434.8 8760
S2:
!"
1 $ 0.99
1.05E $ 10
10869.6 8760
128
Circuit examples
The MTTFd value for block 1 (based on the same assumption) is calculated with:
=
1
1
<
;;
=
>?@
as:
1
1
1
1
1
4
4
4
;;
#A1'
#BC1904'
#BC6900'
#5805'
1
1
1
4
4
4
#5805'
#5805'
#5805'
with:
#S1'
10 #A1'
0.1
#S2'
10 #A2'
0.1
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
#ELxxxx'
#1 $ %&#BCFFF''
!"#BCFFF'
Hence:
#EL1904'
#1 $ 0.99'
G1 $ %&#BC1904'H
0.01
1028.8y
@
I
!"#BC1904'
1.11E $ 09 I 8760 J 9.72E $ 06 @J
#EL6900'
#1 $ %&#BC6900''
#1 $ 0.99'
0.01
1108.6y
!"#BC6900'
1.03E $ 09 @I 8760 IJ 9.02E $ 06 @J
#EL2904'
#1 $ %&#BC2904''
#1 $ 0.99'
0.01
913.2y
!"#BC2904'
1.25E $ 09 @I 8760 IJ 1.1E $ 05 @J
#AX5805'
#1 $ %&#AX5805''
#1 $ 0.99'
0.01
221.7y
@
I
!"#AX5805'
5.15E $ 09 I 8760 J 4.51E $ 05 @J
MTTFd tot=
@
L
L
L
L
L
L
L
R
R
R
R
R
R
NMVM.TQ LSPT.TQ LLST.OQ PPL.WQ PPL.WQ PPL.WQ PPL.WQ
49.8X
129
Circuit examples
UU%
UU%
UU%
UU%
UU% UU% UU% UU%
R
R
R
R
R
R
LVNT.W LSPT.T LLST.O PPL.W PPL.W PPL.W PPL.W
L
L
L
L
L
L
L
R
R
R
R
R
R
R
NMVM.T LVNT.W LSPT.T LLST.O PPL.W PPL.W PPL.W PPL.W
DCavg= NMVM.T
L
99.0%
Category
This structure is possible up to category 4 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
DCavg
Designation
none
low
medium
high
Cat
Range
DC < 60 %
90 % DC < 99 %
90 % DC < 99 %
99 % DC
none
none
low
medium
low
medium
high
low
medium
high
DC
MTTFd
130
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)
131
Circuit examples
Value
EL1904/EL2904
DCavg=0%
1
1
=<
;;
=
>?@
as:
1
1
1
=
+
;;
(BC1904)
(BC2904)
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
(1 $ %&(BCFFF))
!"(BCFFF)
(ELxxxx) =
Hence:
(EL1904) =
(1 $ 0)
G1 $ %&(BC1904)H
1
=
=
= 102881y
!"(BC1904)
1.11E $ 09 @ 8760 IJ 9.72E $ 06 @J
(EL2904) =
(1 $ %&(BC2904))
(1 $ 0)
1
=
=
= 90909.1y
!"(BC2904)
1.25E $ 09 @I 8760 IJ 1.1E $ 05 @J
MTTFd tot=
@
L
L
R
LSPTTLQ USUSU.LQ
S%
S%
USUSU.L
L
R
LSPTTL USUSU.L
DCavg= LSPTTL
L
132
= 48262.6X
= 0%
Circuit examples
Category
This structure is possible up to category 1 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
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
133
Circuit examples
Value
No
No
No
No
Single Logic
Single Logic
EL2904
Parameter
Current measurement active
Output test pulses active
Value
No
No
134
EL6900
EL2904
EL2904
EL1904
EL2904
EL1904
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%
1
1
=<
;;
=
>?@
as:
1
1
1
=
+
;;
(BC1904)
(BC2904)
If only PFH values are available for EL1904 and EL6900, the following estimation applies:
(ELxxxx) =
(1 $ %&(BCFFF))
!"(BCFFF)
Hence:
135
Circuit examples
#EL1904'
#1 $ 0.9'
G1 $ %&#BC1904'H
0.1
!"#BC1904'
1.11E $ 09 @ 8760 IJ 9.72E $ 06 @J
I
10288.1y
#EL2904'
MTTFd tot=
DCavg=
#1 $ 0.9'
G1 $ %&#BC2904'H
0.1
9090.9y
@
I
!"#BC2904'
1.25E $ 09 8760 J 1.1E $ 05 @J
@
L
L
R
LSPTT.LQ USUS.UQ
4826.3X
US%
US%
US%
US%
R
R
R
LSPTT.L LSPTT.L USUS.U USUS.U
L
L
L
L
R
R
R
LSPTT.L LSPTT.L USUS.U USUS.U
90%
Category
This structure is possible up to category 3 at the most.
Notice
MTTFd
Designation for each channel
low
medium
high
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
136
Technical report TV Sd
3 Technical report TV Sd
137
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.
4.1.1
Please contact your Beckhoff branch office or partner company for local support and service on Beckhoff
products!
The contact addresses for your country can be found in the list of Beckhoff branches and partner
companies: www.beckhoff.com. You will also find further documentation for Beckhoff components there.
4.1.2
+ 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:
138
+ 49 (0) 5246/963-460
+ 49 (0) 5246/963-479
service@beckhoff.com