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Publication 1794-RM001G-EN-P - December 2011

Preface

Introduction

This application manual is intended to describe the

FLEX I/O with

ControlLogix

Control System components available from Rockwell Automation that are
suitable for use in SIL2 applications. Use this manual in conjunction with
publication

1756-RM001

Alternate architecture can be used in SIL2 applications if they are approved by
a certifying agency.

Manual Set-Up

This manual is designed to make clear how the

FLEX I/O with

ControlLogix

Control System can be SIL2-certified. Table Preface.1 lists the information
available in each section.

Understanding Terminology

The following table defines acronyms used in this manual.

Table Preface.1

Section:

Title:

Description:

Chapter 1

SIL Policy

Introduction to the SIL policy and how that
policy relates to FLEX I/O with a ControlLogix
system.

Chapter 2

ControlLogix Communications Description of the ControlLogix communications

modules used in the SIL2-certified FLEX I/O
with ControlLogix system.

Chapter 3

FLEX I/O Modules

Description of the FLEX I/O modules used in the
SIL2-certified FLEX I/O with ControlLogix
system.

Chapter 4

General Requirements for
Application Software

Application software requirements for using
ControlLogix and FLEX modules.

Chapter 5

Technical SIL2 Requirements
for the Application Program

Guidelines for application development in
RSLogix 5000 as they relate to SIL2.

Appendix A

Failure Estimates

Failure rates based on field returns.

Table Preface.2 List of Acronyms Used Throughout the Safety Application Manual

Acronym:

Full Term:

Definition:

CIP

Control and
Information
Protocol

A messaging protocol used by Logix5000™
systems. It is a native communications protocol
used on ControlNet™ communications networks,
among others.

Diagnostic
Coverage

The ratio of the detected failure rate to the total
failure rate.

European Norm.

The official European Standard

GSV

Get System Value A ladder logic output instruction that retrieves

specified controller status information and places
it in a destination tag.

AB Drives

Summary of Contents for FlexLogix 1794

Page 1: ...FLEXI OSystemwithControlLogixforSIL2 Catalog Number Bulletin 1794 Reference Manual AB Drives ...

Page 2: ...ty is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Allen Bradley Rockwell Automation FLEX I O...

Page 3: ...nications modules used in the SIL2 certified FLEX I O with ControlLogix system Chapter 3 FLEX I O Modules Description of the FLEX I O modules used in the SIL2 certified FLEX I O with ControlLogix system Chapter 4 General Requirements for Application Software Application software requirements for using ControlLogix and FLEX modules Chapter 5 Technical SIL2 Requirements for the Application Program G...

Page 4: ...000 programming software PFD Probability of Failure on Demand The average probability of a system to fail to perform its design function on demand PFH Probability of Failure per Hour The probability of a system to have a dangerous failure occur per hour 1oo1 One out of one A 1oo1 one out of one architecture consists of a single channel where any dangerous failure leads to a failure of the safety f...

Page 5: ...m is in the maintenance or programming mode the user is responsible for maintaining a safe state For support in creation of programs the PADT Programming and Debugging Tool is required The PADT for ControlLogix FLEX I O is RSLogix 5000 per IEC 61131 3 and this Safety Reference Manual The TUV Rheinland has approved the ControlLogix FLEX I O system for use in up to and including SIL 2 safety related...

Page 6: ...nd Visualization read only access to controllers in the safety loop For more information see publication 1756 RM001 E N B C N B To other safety related ControlLogix or FLEX I O remote I O chassis Overall Safety Loop Actuator Actuator 1794 FLEX I O Input Device DI1 DO2 DO1 DI2 ControlNet Input Device To other safety related ControlLogix or FLEX I O remote I O chassis See Figures 3 1 and 3 5 for det...

Page 7: ...te 1oo1 or 1oo2 configuration Descrete and analog inputs must be used in a 1oo2 configuration for SIL 2 Adapters must be used in a 1oo2 Outputs may be 1oo2 in series or 1oo1 monitored by an input with an external relay as a secondary device to remove power Some specialized inputs can only be wired to a single sensor such as thermocuples and two 1oo1 PFDs must be used for each The total PFD for two...

Page 8: ...ts see Publication 1756 RM001 For more information on the necessary I O module see Table 1 1 IMPORTANT Users specific applications will determine the timeframe for the proof test interval However keep in mind that the Probability of Failure on Demand PFD calculations listed in Table 1 2 on page 1 8 use a proof test interval of once per year If the proof test interval is changed the information mus...

Page 9: ...edia Adapter C 4 3 5 1 5 2 5 3 5 x D 10 1 10 2 10 3 10 x 1794 ACNR15XT C 5 1 5 2 5 3 5 x 1794 IN128 D 10 1 10 2 10 3 10 x 1794 AENT 10 100Mb Ethernet Communication Adapter B 4 1 4 2 4 x 1794 IN082 1794 AENTR A 1 011 1 x 1794 IN131 1794 UM066 1794 AENTRXT I O Modules Digital 1794 IB16 16 Sink Input Module A NA 1794 IN093 NA 1794 IB10XOB6 10 Input 6 Output Module A NA 1794 IN083 1794 OB16 16 Source ...

Page 10: ... D 1794 IN049 1794 UM011 1794 IP4 4 Ch Pulse Counter Module B 4 4 x 1794 IN064 1794 UM016 I O Modules Analog 1794 IE4XOE2XT 4 Input 2 Output Analog Combo Module B NA 1794 IN125 NA 1794 IE8XT 8 Input analog Module B NA 1794 OE4XT 4 Output Analog Module B NA 1794 IF2XOF2IXT 2 Input 2 Output Isolated Analog Combo Module A I I x 1794 IN129 1794 IF4IXT 4 Isolated Input Analog Module A I I x 1794 OF4IXT...

Page 11: ...K versions have the same SIL2 certification as the non K versions 2 The FW versions marked with extension x x can be 0 99 are constitute to minor changes for enhancements The test institute will be informed on any change 3 Users must use these series and firmware revisions for their application to be SIL2 certified Firmware revisions are available by visiting http support rockwellautomation com Co...

Page 12: ...Time Between Failure MTBF 1 λ 3 Calculated PFD 1oo2 architecture 1794 ACN15 ControlNet Single Media Adapter 8 223 684 1 22E 07 2 15E 06 1794 ACNR15 ControlNet Redundant Media Adapter 8 223 684 1 22E 07 2 15E 06 1794 AENT 10 100Mb Ethernet Communication Adapter 691 134 1 45E 06 2 76E 05 1794 AENTR 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 1 45E 05 1794 IB10XOB6 10 Input 6...

Page 13: ...14 771 049 6 77E 08 1 20E 06 1794 IB16XT 16 Sink Input Module 35 587 189 2 81E 08 4 95E 07 1794 OB16PXT 16 Protected Output Module 26 709 401 3 74E 08 6 60E 07 1794 IB10XOB6XT 10 Input 6 Output Combo Module 22 202 487 4 50E 08 7 94E 07 1794 OW8XT 8 Relay Output Module 18 518 519 5 40E 08 9 53E 07 1794 IE4XOE2XT 4 Input 2 Output Analog Combo Module 11 800 802 8 47E 08 1 50E 06 1794 IE8XT 8 Input an...

Page 14: ...1794 OB16 16 Source Output Module 1 883 594 5 31E 07 3 96E 09 1794 OB16P Protected Output Module 2 135 280 4 68E 07 3 47E 09 1794 OB8EP Protected Output Module 2 389 669 2 4 18E 07 3 08E 09 1794 OE4 Analog Output Module 23 807 086 4 20E 08 2 96E 10 1794 OF4I Isolated Analog Output Module 7 191 128 1 39E 07 9 90E 10 1794 OW8 Relay Output Module 14 766 876 6 77E 08 4 78E 10 1794 TB3 Terminal Base Un...

Page 15: ...794 IRT8XT 8 TC RTD Input Analog Module 8 204 792 1 22E 07 8 66E 10 1 MTBF measured in hours 2 Calculated using field based values for components 3 λ Failure Rate 1 MTBF Table 1 3 FLEX I O Product Probability of Undetected Dangerous Failure per Hour PFH Calculations T1 1 yr Catalog Number Description Mean Time Between Failure MTBF 1 λ 3 Calculated PFH 1oo2 architecture Table 1 4 Catalog Number Des...

Page 16: ...Publication 1794 RM001G EN P December 2011 1 12 SIL Policy B B 1794 OB16 1794 IB16 1794 TB3 1 1794 TB3 2 1794 ACNR15 1 1794 ACNR15 2 1794 IB16 1794 OW8 1756 CNB 1756 L63B ControlNet ControlNet 1756 CNB ...

Page 17: ...as the amount of time it takes for a change in an input condition to be recognized and processed by the controller s ladder logic program and then to initiate the appropriate output signal to an actuator The system response time is the sum of the following input hardware delays input filtering I O and communication module RPI settings controller program scan times output module propagation delays ...

Page 18: ...Publication 1794 RM001G EN P December 2011 1 14 SIL Policy Notes ...

Page 19: ... to use redundant media with the 1756 CNBR it does provide higher system availability Redundant media is not required for SIL2 operation ControlNet Module Diagnostic Coverage All communications over the passive ControlNet media occur via CIP which guarantees delivery of the data All modules independently verify proper transmission of the data EtherNet IP Bridge Module The EtherNet IP bridge module...

Page 20: ... Entry Status attribute for a running connection An example of how this might be done is shown in Figure 2 1 This method or something similiar must be used to interrogate the health of each I O module in the system Figure 2 1 Example of Checking a Module s Health in Ladder Logic For more information on the GSV instruction monitor the SlotStatusBits for the Input tag of the associated adapter The l...

Page 21: ...ommunications modules see the following Rockwell Automation publications listed in Table 2 1 These publications are available from Rockwell Automation at http literature rockwellautomation com Module 0 Module 1 Module 2 Module 3 Module 4 Module 5 Module 6 Module 7 Table 2 1 Catalog Number Description Installation Instructions User Manual 1756 CNB ControlNet Communication Module 1756 IN571 CNET UM0...

Page 22: ...Publication 1794 RM001G EN P December 2011 2 4 ControlLogix Communications ...

Page 23: ... FLEX I O modules are designed with inherent features that assist them in complying with the requirements of the 61508 Standard For example the modules all have a common backplane interface execute power up and runtime diagnostics and offer electronic keying Table 1 1 lists the FLEX I O modules initially submitted for SIL2 certification For information about See page Overview of FLEX I O Modules 3...

Page 24: ...a System Validation test must be performed Manually or automatically test inputs to make sure that all inputs are operational and not stuck in the ON or OFF state Inputs must be cycled from ON to OFF or OFF to ON Wire sensors to separate input points on two separate modules that are on different ControlNet nodes Configuration parameters for example RPI filter values must be identical between the t...

Page 25: ...3 Input 1 Input 2 Input COM 24V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 24VDC SINK INPUT 1794 IB16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 24VDC SINK INPUT 1794 IB16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 24VDC SINK INPUT 1794 IB16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 24VDC SINK INPUT 1794 IB16 Input COM 24V Input 1 Input 2 SIL2 SENSOR SENSOR SENSOR 24V dc Optional relay contact to switch line voltage...

Page 26: ...ke sure that all outputs are operational and not stuck in the ON or OFF state Outputs must be cycled from ON to OFF or OFF to ON For additional information refer to publication 1756 RM001 Figure 3 4 The control diagnostics and alarming functions must be performed in sequence Use of external Relays to disconnect Module Power if Output De energization is Critical To make sure outputs will de energiz...

Page 27: ...n the event of a miscompare between the requested state of an output echo and the actual output state monitored by an input channel see Figure 3 4 The control diagnostics and alarming functions must be performed in sequence 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 24VDC SOURCE OUTPUT 1794 OB16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 24VDC SINK INPUT 1794 IB16 Standard Digital Output Module 43363 Standa...

Page 28: ...LEX I O Standard Output Module Wiring With an Isolated Relay Module 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 24VDC SINK INPUT 1794 IB16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 24VDC SOURCE OUTPUT 1794 OB16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 24VDC SOURCE OUTPUT 1794 OB16 Isolated Relay Output Module 43364 Standard Digital Input Module Standard Digital Output Module 24V COM Wire output point to input ...

Page 29: ...etermine a tolerance band of accuracy for a specific application The user can then measure input values on multiple channels and compare those values to acceptable values within the tolerance band Based on the differences in the comparison the user could then determine whether recalibration is necessary Calibration and subsequent recalibration is not a safety issue However we recommend that each a...

Page 30: ...in sequence Configuration parameters for example RPI filter values must be identical between the two modules The same controller must own both modules Monitor the ControlNet status bits for the associated module and ensure that appropriate action is invoked via the application logic by these status bits Wire sensors to separate input channels on two separate modules that are on different ControlNe...

Page 31: ...hen using Any FLEX I O Analog Input Module on page 3 7 make sure you use the correct documentation listed in Table 1 1 on page 1 5 to wire the module Figure 3 9 FLEX I O Analog Input Module Wiring in Voltage Mode Input 1 Input 2 Input COM 24V Input COM 24V Input 1 Input 2 SIL2 SENSOR SENSOR 43366A One Sensor Wiring Example Two Sensor Wiring Example SENSOR Note 1 Both sensors are monitoring the sam...

Page 32: ...ation guideline Placement of Other Devices in Current Loop you can locate other devices in an input channel s current loop anywhere as long as the current source can provide sufficient voltage to accommodate all of the voltage drops each module input is 250 ohms RET RET RET RET Current Source B Current Source B Current Source A Current Source A 1794 TB3 1794 TB3 1794 TB3 1794 TB3 1794 IE8 Analog I...

Page 33: ...ation guideline Wire to Same Input Channel on Both Modules When wiring thermocouples wire two in parallel to two modules Use the same channel on each module to make sure of consistent temperature readings Figure 3 10 FLEX I O Analog Thermocouple Module Wiring Thermocouple Input Module Thermocouple Input Module Thermocouple RTD mV Input Module Thermocouple RTD mV Input Module 1794 TB3T 1794 TB3T 17...

Page 34: ...pplication guideline RTDs cannot be wired in parallel without severely affecting their accuracy Two sensors must be used Figure 3 11 FLEX I O Analog RTD Module Wiring RTD Input Module RTD Input Module Thermocouple RTD mV Input Module Thermocouple RTD mV Input Module 1794 TB3T 1794 TB3T 1794 TB3G 1794 TB3G 1794 IR8 1794 IR8 1794 IRT8 1794 IRT8 4 Wire RTD 3 Wire RTD Note 2 3 or 4 wire RTDs can be us...

Page 35: ...properly calibrated for their specific application Users can employ tests in application program logic to determine when a module requires recalibration For example to determine whether an output module needs to be recalibrated a user can determine a tolerance band of accuracy for a specific application The user can then measure output values on multiple channels and compare those values to accept...

Page 36: ...log input and output that is range and the result is stored that is delta This delta value is then added to and subtracted from the monitoring analog input channel the results define an acceptable High and Low limit of deviation The analog Output Feedback is then compared to these limits to determine if the output are working properly The output s OK bit preconditions a Timer run that is preset to...

Page 37: ...utput modules in the same application make sure Both modules use identical configuration The same controller owns both modules Monitor the ControlNet status bits for the associated module and ensure that appropriate action is invoked via the application logic by these status bits AB Drives ...

Page 38: ...ake sure that the output is functioning properly Wiring the Analog Output Module in Voltage Mode Users must wire analog outputs to an actuator and then back to an analog input to monitor the output performance _ V RET _ V RET 1794 TB3 1794 IF4I Analog Output Module 1794 TB3 1794 IE8 Analog Input Module Isolated Analog Output Module Isolated Analog Input Module 1794 OF4I 1794 TB3 1794 TB3 Actuator ...

Page 39: ...ne before wiring the module in current mode Placement of Other Devices in Current Loop you can locate other devices in an output channel s current loop anywhere as long as the current source can provide sufficient voltage to accommodate all of the voltage drops _ _ 1794 TB3 1794 IF4I Analog Output Module 1794 TB3 1794 IE8 Analog Input Module Isolated Analog Output Module Isolated Analog Input Modu...

Page 40: ...ssociated module and is appropriate action invoked via the application logic by these bits No Additional Digital Input Module Only Requirements Yes No Comment 1 When two digital input modules are wired in the same application do the following conditions exist Both modules are owned by the same controller Sensors are wired to separate input points The operational state is ON The non operational sta...

Page 41: ... on the module or isolated output in series 5 Is the control of the external relay implemented in ladder logic 6 Have you examined the Output Data feedback signal in application logic 7 Are all outputs configured to deenergize in the event of a fault or the controller entering program mode 8 Do two modules of the same type used in the same application use identical configurations 9 Does one contro...

Page 42: ...Publication 1794 RM001G EN P December 2011 3 20 FLEX I O Modules Notes ...

Page 43: ...1 Publication 1794 RM001G EN P December 2011 Chapter 4 General Requirements for Application Software Refer to publication 1756 RM001 Using ControlLogix in SIL2 Applications AB Drives ...

Page 44: ...Publication 1794 RM001G EN P December 2011 4 2 General Requirements for Application Software Notes ...

Page 45: ...lication 1794 RM001G EN P December 2011 Chapter 5 Technical SIL2 Requirements for the Application Program Refer to publication 1756 RM001 for Technical SIL2 Requirements for the application program AB Drives ...

Page 46: ...Publication 1794 RM001G EN P December 2011 5 2 Technical SIL2 Requirements for the Application Program Notes ...

Page 47: ...5E 06 1794 IP4 Pulse Counter Module 2 375 360 4 21E 07 7 58E 06 1794 IR8 RTD Input Module 6 191 655 1 62E 07 2 87E 06 1794 IRT8 TC RTD mV Input Module 1 182 438 8 46E 07 1 56E 05 1794 IT8 Thermocouple Input Module 1 564 324 6 39E 07 1 17E 05 1794 OB16 16 Source Output Module 1 883 594 5 31E 07 9 62E 06 1794 OB16P Protected Output Module 2 135 280 4 68E 07 8 46E 06 1794 OB8EP Protected Output Modul...

Page 48: ...8XT 8 TC RTD Input Analog Module 8 204 792 1 22E 07 2 16E 06 1 MTBF measured in hours 2 Calculated using field based values for components 3 λ Failure Rate 1 MTBF Table A 1 MTBF Field Data and Per Module PFD Estimates T1 1 year Catalog Number Description MTBF 1 λ 3 Estimated PFD 1oo2 Table A 2 MTBF Field Data and Per Module PFD Estimates T1 2 years Catalog Number Description MTBF 1 λ 3 Estimated P...

Page 49: ...94 AENTRXT 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 3 02E 05 1794 OB8EPXT 8 Protected Output Module 14 771 049 6 77E 08 2 40E 06 1794 IB16XT 16 Sink Input Module 35 587 189 2 81E 08 9 90E 07 1794 OB16PXT 16 Protected Output Module 26 709 401 3 74E 08 1 32E 06 1794 IB10XOB6XT 10 Input 6 Output Combo Module 22 202 487 4 50E 08 1 59E 06 1794 OW8XT 8 Relay Output Module 18 ...

Page 50: ...le 1 564 324 6 39E 07 6 62E 05 1794 OB16 16 Source Output Module 1 883 594 5 31E 07 5 36E 05 1794 OB16P Protected Output Module 2 135 280 4 68E 07 4 65E 05 1794 OB8EP Protected Output Module 2 389 669 2 4 18E 07 4 10E 05 1794 OE4 Analog Output Module 23 807 086 4 20E 08 3 73E 06 1794 OF4I Isolated Analog Output Module 7 191 128 1 39E 07 1 27E 05 1794 OW8 Relay Output Module 14 766 876 6 77E 08 6 0...

Page 51: ...d PFD 1oo2 Table A 4 MTBF Field Data and Per Module PFH Estimates T1 1 year Catalog Number Description MTBF 1 λ 3 Estimated PFH 1oo2 1794 ACN15 ControlNet Single Media Adapter 8 223 684 1 22E 07 8 64E 10 1794 ACNR15 ControlNet Redundant Media Adapter 8 223 684 1 22E 07 8 64E 10 1794 AENT 10 100Mb Ethernet Communication Adapter 691 134 1 45E 06 1 19E 08 1794 AENTR 10 100Mb Ethernet Redundant Commun...

Page 52: ...794 OB8EPXT 8 Protected Output Module 14 771 049 6 77E 08 4 78E 10 1794 IB16XT 16 Sink Input Module 35 587 189 2 81E 08 1 97E 10 1794 OB16PXT 16 Protected Output Module 26 709 401 3 74E 08 2 63E 10 1794 IB10XOB6XT 10 Input 6 Output Combo Module 22 202 487 4 50E 08 3 17E 10 1794 OW8XT 8 Relay Output Module 18 518 519 5 40E 08 3 80E 10 1794 IE4XOE2XT 4 Input 2 Output Analog Combo Module 11 800 802 8...

Page 53: ...564 324 6 39E 07 5 17E 09 1794 OB16 16 Source Output Module 1 883 594 5 31E 07 4 20E 09 1794 OB16P Protected Output Module 2 135 280 4 68E 07 3 65E 09 1794 OB8EP Protected Output Module 2 389 669 2 4 18E 07 3 23E 09 1794 OE4 Analog Output Module 23 807 086 4 20E 08 2 97E 10 1794 OF4I Isolated Analog Output Module 7 191 128 1 39E 07 1 01E 09 1794 OW8 Relay Output Module 14 766 876 6 77E 08 4 82E 10...

Page 54: ...Estimates T1 2 years Catalog Number Description MTBF 1 λ 3 Estimated PFH 1oo2 Table A 6 MTBF Field Data and Per Module PFH Estimates T1 5 years Catalog Number Description MTBF 1 λ 3 Estimated PFH 1oo2 1794 ACN15 ControlNet Single Media Adapter 8 223 684 1 22E 07 9 14E 10 1794 ACNR15 ControlNet Redundant Media Adapter 8 223 684 1 22E 07 9 14E 10 1794 AENT 10 100Mb Ethernet Communication Adapter 691...

Page 55: ...268 070 7 89E 07 8 17E 09 1794 OB8EPXT 8 Protected Output Module 14 771 049 6 77E 08 4 93E 10 1794 IB16XT 16 Sink Input Module 35 587 189 2 81E 08 2 00E 10 1794 OB16PXT 16 Protected Output Module 26 709 401 3 74E 08 2 68E 10 1794 IB10XOB6XT 10 Input 6 Output Combo Module 22 202 487 4 50E 08 3 24E 10 1794 OW8XT 8 Relay Output Module 18 518 519 5 40E 08 3 90E 10 1794 IE4XOE2XT 4 Input 2 Output Analo...

Page 56: ...Publication 1794 RM001G EN P December 2011 A 10 Failure Estimates Notes ...

Page 57: ... 4 Digital output modules 3 6 Fault reporting 3 3 3 4 3 5 3 7 3 14 Proof tests 3 2 3 4 3 7 3 13 Wiring analog input modules 3 9 3 15 Wiring analog output modules 3 16 3 17 Wiring digital input modules 3 3 Wiring digital output modules 3 5 3 6 M Mean time between failures MTBF Definition Preface 2 Mean time to restoration Definition Preface 2 P Probability of failure on demand PFD 1 8 1 11 Calculat...

Page 58: ...Publication 1794 RM001G EN P December 2011 2 Index Wiring I O modules Analog input modules 3 9 3 15 Analog output modules 3 16 3 17 Digital input modules 3 3 Digital output modules 3 5 3 6 ...

Page 59: ...AB Drives ...

Page 60: ...oblem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning...

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