EL6900 Bornier logique TwinSAFE EtherCAT

Product Overview

The EL6900 (EL6900) is a dedicated safety controller designed to function as the central link unit between safe input and output signals within an EtherCAT network. Utilizing the Safety over EtherCAT (FSoE) protocol, this terminal enables the implementation of complex safety functions directly within the I/O segment. In high-risk industrial environments—such as robotic work cells, automated assembly lines, and material handling systems—the EL6900 is essential for managing emergency stops, light curtains, and safety door monitoring. By offloading safety logic from the standard PLC to this specialized hardware, the system achieves the highest safety ratings, including SIL 3 according to EN 61508 and PL e according to ISO 13849-1, ensuring maximum protection for both personnel and equipment.

Technical Configuration

The EL6900 operates as a TwinSAFE Logic terminal, capable of processing up to 128 safety connections. It serves as the "Safety Master" in a decentralized safety architecture, communicating with various TwinSAFE-capable input and output modules. The terminal features a fast cycle time of approximately 500 µs (project size dependent) and a parameterizable fault response time, allowing for deterministic safety reactions. Because it draws power exclusively from the E-bus (typically 188 mA), it requires no additional field power contacts for logic operation. The configuration and safety logic are programmed via the TwinSAFE Configurator within the TwinCAT environment, providing a seamless integration between standard control and functional safety.

Technical Specifications

Technical FAQs

Can the EL6900 control safety functions independently of the main PLC?

Yes. While the EL6900 resides in the EtherCAT terminal stack and communicates via the main PLC, the safety logic is executed locally within the EL6900's safe processor. Even if the standard PLC stops or encounters an error, the EL6900 maintains the ability to drive the safety system into a "Safe State" independently.

How many safety devices can be managed by a single EL6900 terminal?

The EL6900 supports up to 128 safe connections. This means it can monitor and control a wide array of safe sensors and actuators (FSoE Slaves) across the network, making it suitable for medium to large-scale safety applications.

What happens if the communication between safety modules is interrupted?

The EL6900 monitors communication via a parameterizable "Watchdog Time." If the safety telegram does not arrive within this window—due to a cable break or excessive noise—the EL6900 will automatically initiate the programmed fault response to ensure the system remains in a safe condition.

Engineering & Installation Guide

• Safety Project Validation: After programming the safety logic in TwinCAT, the project must be verified and downloaded to the EL6900 using a secure procedure. Always document the generated CRC (Cyclic Redundancy Check) checksum; this unique identifier ensures that the hardware is running the exact authorized version of the safety code.

• E-bus Power Calculation: The EL6900 has a relatively high K-bus/E-bus current draw (188 mA). When designing your terminal segment, ensure that the EtherCAT Coupler or the preceding Power Supply terminal provides enough current for the EL6900 and all subsequent safety I/O modules to prevent communication dropouts.

• Wiring and ESD Safety: Use a screwdriver to actuate the spring terminals for secure connections. While the EL6900 does not use power contacts, the surrounding wiring should follow strict ESD protection protocols. Ensure the DIN rail is properly grounded to provide a low-impedance path for electromagnetic interference, which is critical for maintaining "Error-Free" safety communication.