Safety in the Block

However, regardless of the protection type, the reality of machine and system building is only covered in a limited way by the range of safety-related products offered from fieldbus manufacturers. The offering consists mainly of either pure safety I/O modules or standard I/O modules. This is the case even though the planning and installation in the field almost always involves a different number of standard and safety signals. Safety signals must be brought to the controller directly next to standard signals. Until now, however, there have been no I/O modules that can bring both safety signals and also standard signals to the controller. For IP67 wiring in the machine, the user could previously only choose between either pure safety or pure standard modules. There were often too many unused channels left over – either on the standard or the safety I/O modules. The alternatives of a point-to-point wiring or a separate safety controller require extensive wiring.

TBPN-L1-FDIO1 hybrid safety I/O module

Turck has closed this gap with its TBPN-L1-FDIO1 I/O module. The hybrid module combines four safety Profinet/Profisafe channels and four standard I/Os. It offers two safety-related inputs for Profisafe to which two-channel safety components such as mechanical safety switches or also electronic safety sensors with OSSD signals such as light curtains can be connected. Two universal digital channels are also provided as safety-related inputs or outputs.

Flexibility through two IO-Link masters

On the standard side the new module offers four universal inputs or outputs. Two of them can even be defined alternatively as IO-Link masters, which considerably increases the application range of the modules. Through the use of Turck I/O hubs on both IO-Link masters, users can keep the wiring effort required for additional standard signals down to a minimum. With two I/O hubs up to 32 additional digital signals can be connected via IO-Link. This flexibility of the module simplifies the engineering of machines and minimizes the number of unused channels. As more standard I/Os than safety I/Os are required in most cases, the TBPN with its IO-Link option is a clever solution.

Remote logic speeds up the reaction time

The TBPN-L1-FDIO1 does more than only offer highly flexible inputs and outputs for safety and standard signals. With its onboard logic function the hybrid module can operate as a remote compact safety controller at the same time. The user benefits from the shorter reaction time of the overall system and allows for this in machine and plant design. Without the remote logic the triggering signal must first reach the distant safety controller via Profisafe, be processed by it and then sent to the actuators to be controlled. The overall reaction time of the system is thus longer than a local disconnection directly at the device using Turck’s hybrid module. This means, for example, that a shorter gap between a light curtain and a hazardous movement can be designed than with a conventional safety PLC solution.

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GSDML file and configuration software

The logic functions and the properties of the safety-related I/Os are defined using Turck’s Safety Configurator for safety channels. This is necessary for every application since different safety components with different behaviors make an individual selection necessary. The Safety Configurator is based on MS Windows and enables rapid configuration of the safety I/Os thanks to its intuitive interface. The standard I/Os are configured using a GSDML file as is customary with all Profinet modules. The web server of the device simplifies its diagnostics and commissioning.

Memory stick saves repeat configurations

To save the customer having to reconfigure modules in the event of a fault, these are fitted with a pluggable memory stick. The Turck Safety Configurator not only saves the set safety properties in the TBPN module but also on the stick. If a replacement is required, you simply pull out the memory stick on the faulty module and fit it in the replacement device. After the power supply is switched on, the configuration data is automatically transferred to the new module and operation can continue safely unchanged.

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