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Rockwell Automation Publication 1756-RM012B-EN-P - April 2018

Chapter 6

Safety Application Development

Active simulation with sources (field devices) must also be included, as it is the

only way to verify that the sensors and actuators in the system are wired

correctly. Verify the operation of programmed functions by manipulating

sensors and actuators manually.

You must also include tests to verify the reaction to wiring faults and network

communication faults.

Project validation includes tests of fault routines, and input and output

channels, to be sure that the safety system operates properly.

To perform a project validation test on the GuardLogix controller, you must

perform a full test of your application. You must toggle each sensor and

actuator that is involved in every safety function. Be sure to test all shutdown

functions, because these functions are not typically exercised during normal

operation.

Also, know that a project validation test is valid only for the specific

application tested. If the safety application is moved to another installation,

you must perform start-up and project validation on the safety application in

the context of the new sensors, actuators, wiring, networks, and control system

physical equipment.

Confirm the Project

You must print or view the project, and compare the uploaded safety I/O and

controller configurations, safety data, and safety task program logic to make

sure that the correct safety components were downloaded, tested, and retained

in the safety application program.

If your application program contains a safety Add-On Instruction that has

been sealed with an instruction signature, you must also compare the

instruction signature, date/time, and safety instruction signature to the values

you recorded when you sealed the Add-On Instruction.

See

Appendix B

page 73

for information about the creation and use of

safety Add-On Instructions in SIL 3 applications.

The following steps illustrate one method for confirming the project.

1. While online with the controller, and with the controller in Program

mode, save the project.

2. Answer Yes to the Upload Tag Values prompt.
3. With the Studio 5000 Logix Designer application offline, save the

project with a new name, such as Offlineprojectname.ACD, where

'projectname' is the name of your project. This file is the new tested

master project file.

4. Close the project.

Содержание Compact GuardLogix 5380

Страница 1: ...756 L8SPK 5069 L306ERMS2 5069 L306ERS2 5069 L310ERMS2 5069 L310ERS2 5069 L320ERMS2 5069 L320ERS2 5069 L320ERS2K 5069 L320ERMS2K 5069 L330ERMS2 5069 L330ERS2 5069 L330ERS2K 5069 L330ERMS2K 5069 L340ERM...

Страница 2: ...nformation 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 T...

Страница 3: ...GuardLogix Controller System GuardLogix 5580 Controller Hardware 15 Primary Controller 16 Safety Partner 16 Chassis 16 Power Supply 16 Compact GuardLogix 5380 Controller Hardware 17 Power Supply 18 N...

Страница 4: ...Modules 40 Use of Human Machine Interfaces 42 Precautions 42 Access to Safety related Systems 43 Safety Programs 44 Safety Routines 44 Safety Tags 45 Standard Tags in Safety Routines Tag Mapping 46 Ch...

Страница 5: ...erable Safety Faults in the Safety Application 67 View Faults 68 Fault Codes 68 Safety Partner Fault 68 AppendixA Safety Instructions Safety Instructions 69 AppendixB Create and Use a Safety Add On In...

Страница 6: ...View the Input and Output Safety Connection Reaction Time Limits 84 Configure the Safety Task Period and Watchdog 86 Access Produced Consumed Tag Data 86 AppendixD Checklists for GuardLogix Safety Ap...

Страница 7: ...ix 5580 or Compact GuardLogix 5380 controller based safety system Summary of Changes This manual contains new and updated information as indicated in the following table Terminology This section defin...

Страница 8: ...ibes how to install the 5069 OBV8S module Compact 5000 Digital and Safety I O Modules User Manual publication 5000 UM004 Describes how to use Compact 5000 digital and safety I O modules including how...

Страница 9: ...If Device Failure Occurs 14 Controller System IEC 61508 IEC 62061 ISO 13849 1 Type approved and certified for use in safety applications up to and including Suitable for use in safety applications up...

Страница 10: ...x 5580 and Compact GuardLogix 5380 controllers have a useful life of 20 years no proof test required Other components of the system such as safety I O devices sensors and actuators can have different...

Страница 11: ...tside the function Figure 1 Example SIL 3 System OK Logix55L8SP NET LINK RUN REM RUN PROG FORCE SD OK Logix5584ES DCINPUT 5069 OBV8S COUNTER 5069 HSC2xOB4 DC INPUT 5069 IB16 DC OUTPUT 5069 OB16 5069 I...

Страница 12: ...T 5069 IB16 DC OUTPUT 5069 OB16 5069 IB8S OUTPUT 5069 OBV8S COUNTER 5069 HSC2xOB4 DC INPUT 5069 IB16 DC OUTPUT 5069 OB16 5069 IB8S OUTPUT Compact I O Actuator Sensor 5069 AEN2TR Compact 5000 I OModule...

Страница 13: ...system until the time that the system is in the safe state This worst case definition includes the effects of asynchronous communications and multiple potential faults occurring within the system Actu...

Страница 14: ...s than or equal to the safety task period The safety task watchdog time is set in the task properties window of the Studio 5000 Logix Designer application This value can be modified online regardless...

Страница 15: ...at is used with a safety partner is up to SIL 3 For the most current list of GuardLogix controller and Safety I O devices certified series and firmware revisions see the safety certificates at http ww...

Страница 16: ...is a major non recoverable controller fault For information on how to respond to this situation see article 63983 in the Rockwell Automation Knowledgebase For SIL 2 requirements do not install a safet...

Страница 17: ...tomation com global certification overview page Controller Cat No Compact GuardLogix 5380 controller 5069 L306ERMS2 5069 L306ERS2 5069 L310ERMS2 5069 L310ERS2 5069 L320ERMS2 5069 L320ERS2 5069 L320ERS...

Страница 18: ...I O power must be connected to a catalog number 5069 FPD module Network Communication This section provides examples of network communication configurations EtherNet IP Network The GuardLogix 5580 co...

Страница 19: ...OD NET MOD NET MOD NET 2 1 1 1 4 I O I O 6 5 10 2 1 2 1 2 1 1 I O A 6 5 10 1 I O B 6 5 10 1 I O A 6 1 I O B 6 5 10 5 10 UFB UFB A UFB B UFB A UFB B D D D D D D MF A MF B MF A MF B D D MBRK MOD NET 2 1...

Страница 20: ...GuardLogix DC INPUT 5069 IB16 DC OUTPUT 5069 OB16 5069 IB8S OUTPUT 5069 OBV8S COUNTER 5069 HSC2xOB4 DC INPUT 5069 IB16 DC OUTPUT 5069 OB16 5069 IB8S OUTPUT 5069 OBV8S COUNTER 5069 HSC2xOB4 DC INPUT 50...

Страница 21: ...NS LOCK 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 IN PWR OUT PWR 1791DS CompactBlock Guard I OModule DeviceNet Network 1732DSArmorBlock Guard I O Module 1732DSArmorBlock Guard I O Module 1791DS CompactBlock Gu...

Страница 22: ...o define the location ownership and configuration of I O devices and controllers and create test and debug program logic Only ladder diagram is supported in the GuardLogix safety task See Appendix A o...

Страница 23: ...ol safety logic is processed in the GuardLogix controller Typical Safety Functions of Safety I O Devices The following is treated as the safe state by Safety I O devices Safety outputs OFF Safety inpu...

Страница 24: ...t signals In some applications you must include off delay on delay or both when you calculate system reaction time For example the On to Off delay filter helps to filter out noise that affects the inp...

Страница 25: ...oller controls safety output devices One controller also owns each safety input device However safety input data can be shared consumed by multiple GuardLogix controllers Safety I O Configuration Sign...

Страница 26: ...erly configured and that the operation of the replacement device is verified Two options for I O device replacement are available on the Safety tab of the Controller Properties dialog box in the Studi...

Страница 27: ...ce electronic keying is correct The node or IP address is correct To set the proper safety network number SNN when a controller safety signature exists a manual action is required to download the prop...

Страница 28: ...inSIL2orSIL 3behavior during the replacement and functional testing of a device See Routable CIP Safety System on page 30 IfotherpartsoftheSafetycontrolsystemarebeingreliedupontomaintainSIL2 or SIL 3...

Страница 29: ...ique Node ID or UNID Every CIP Safety device must have a UNID value assigned to each CIP Safety capable port Safety Network Numbers SNN Communications within a control system travel over subnets that...

Страница 30: ...for Assigning SNNs When creating controller projects the Studio 5000 Logix Designer application generates an SNN value automatically whenever it recognizes a new subnet that contains CIP Safety devic...

Страница 31: ...S Switch Switch 5069 L320E RS2 1732DS IB6 1732ES IB16 1732DS IBSXOBV4 1791ES IB16 1756 L71S 1756 DNB 1756 L7SP 1756 EN2T 1756 L84ES 1756 L81ES SNN_1 1756 Backplane SNN_2 SNN_3 SNN_5 5069 Backplane SNN...

Страница 32: ...a new SNN is generated for the first CIP Safety device on that subnet We recommend that you assign each controller SNN to the already established SNN for the subnet This allows the Studio 5000 Logix...

Страница 33: ...NNs generated by the software are always unique to the project whether generated by project creation or IP mode change Devices that are created directly under the controller port default to having the...

Страница 34: ...ng user manuals for information on how to change the SNN ControlLogix 5580 and GuardLogix 5580 Controllers User Manual publication 1756 UM543 CompactLogix 5380 Controllers User Manual publication 5069...

Страница 35: ...PORTANT Toadd aCIPSafety I Odevice toaconfiguredGuardLogixsystem theSNNis present in the GuardLogix controller the replacement CIP Safety I O device must have the correct SNN applied before it is adde...

Страница 36: ...36 Rockwell Automation Publication 1756 RM012B EN P April 2018 Chapter 4 CIP Safety and Safety Network Numbers Notes...

Страница 37: ...ollers also provide a SIL 2 or SIL 3 capable safety task However a logical and visible distinction is required between the standard and safety related portions of the application The Studio 5000 Logix...

Страница 38: ...ctuations in execution time which can allow a lower setting for the safety task watchdog which improves the reaction time of the safety system Safety Task Limitations You specify both the safety task...

Страница 39: ...imer related instructions such as TON and TOF are not updated during a safety task execution They keep accurate time from one task execution to another but the accumulated time is not changed during s...

Страница 40: ...devices are typically required for SIL 3 IMPORTANT While safety unlocked and without a safety signature the controller helps prevent simultaneous write access to safety memory from the safety task and...

Страница 41: ...s Safety Time greater than 600 ms the typical safety I O pulse test interval or the demand rate must be less than one demand per minute for example one per hour CompactBlock Guard I O 1791 series Armo...

Страница 42: ...curity Specifications testing and validation Restrictions on data and access Limits on data and parameters For more information on how HMI devices fit into a typical SIL loop see GuardLogix Architectu...

Страница 43: ...oop You must clearly document variables that are to be changed You must use a clear comprehensive and explicit operator procedure to make safety related changes via an HMI Changes can be accepted in a...

Страница 44: ...data points Similar to the controller program the HMI software is secured and maintained for SIL level compliance after the system has been validated and tested Safety Programs A safety program has t...

Страница 45: ...the direct creation of invalid tags in a safety program If invalid tags are imported they cannot be verified Tags that are classified as safety tags are either controller scoped or program scoped Eit...

Страница 46: ...iable means to make sure that the data is used in an appropriate manner The use of standard data in a safety tag does not make it safety data You must not directly control a safety output with standar...

Страница 47: ...l application downloads via a manual check of the safety signature You perform a complete functional test of the entire system before the operational startup of a safety related system This test inclu...

Страница 48: ...le 2 Safety Application Status Safety Task Status Safety 1 up to and including Controller Behavior Unlocked No signature Only for development purposes Safety I O forces can be present Safety I O force...

Страница 49: ...e mechanisms that may affect the executable software when the Studio 5000 Logix Designer application is used in a manner other than what is specified in the product documentation You must verify that...

Страница 50: ...of the Safety Function on page 51 Create the Project on page 52 Online Create the Project on page 52 Offline Attach to Controller and Download Test the Application Program on page 52 Generate the Saf...

Страница 51: ...which includes the following Input definitions Output definitions I O wiring diagrams and references Theory of operation Matrix or table of stepped conditions and the actuators to be controlled includ...

Страница 52: ...edits upload and download and informal testing that is required to get an application running properly in preparation for the Project Validation test Generate the Safety Signature The safety signatur...

Страница 53: ...d within the safety task Online or offline programming or editing of safety components Forcing safety I O Data manipulation of safety components except through routine logic or another GuardLogix cont...

Страница 54: ...start up and project validation on the safety application in the context of the new sensors actuators wiring networks and control system physical equipment Confirm the Project You must print or view...

Страница 55: ...GuardLogix controller and CIP Safety I O devices Compare all properties of the safety task safety programs and safety routines Compare all logic in the safety routines 10 Verify that all controller a...

Страница 56: ...are optional For more information about the safety lock feature see the user manual for the controller ControlLogix 5580 and GuardLogix 5580 Controllers User Manual publication 1756 UM543 CompactLogix...

Страница 57: ...ry card match the major and minor revisions of your controller If your controller is not in Run mode Loading a project to a safety locked controller is allowed only when the safety signature of the pr...

Страница 58: ...s for editing safety logic online If the controller is locked with safety edits you must unlock the controller to assemble or cancel the edits For safety routines the controller cannot be locked when...

Страница 59: ...ty of the system You must sufficiently document all program edits which include the following Authorization Impact analysis Execution Test information Revision information If online edits exist only i...

Страница 60: ...der Logic in the Studio 5000 Logix Designer application while online see the Logix5000 Controllers Quick Start publication 1756 QS001 Modification Impact Test Any modification enhancement or adaptatio...

Страница 61: ...anges Yes No Delete Safety Application Signature Make Desired Modifications to Safety Logic Attach to Controller and Download Make Desired Modifications to Standard Logic Attach to Controller and Down...

Страница 62: ...62 Rockwell Automation Publication 1756 RM012B EN P April 2018 Chapter 6 Safety Application Development Notes...

Страница 63: ...System Status You can view the status of safety tag connections You can also determine current operating status by interrogating various device objects It is your responsibility to determine what data...

Страница 64: ...onnectionFaulted Status Safety Connection Operation 1 Run 0 Valid The producing device is actively controlling the data The producing device is in Run mode 0 Idle 0 Valid The connection is active and...

Страница 65: ...ystem GuardLogix controllers are part of a de energize to trip system which means that zero is the safe state Some but not all safety I O device faults cause all device inputs or outputs to be set to...

Страница 66: ...ication 1756 RM003 Safety Faults Faults in the GuardLogix 5580 and Compact GuardLogix 5380 system can be Recoverable controller faults Nonrecoverable controller faults Nonrecoverable safety faults in...

Страница 67: ...fety protocol connections are closed and reopened to reinitialize them Safety outputs are placed in the safe state and the producer of safety consumed tags commands the consumers to place them in a sa...

Страница 68: ...in the slot next the Safety Primary these actions occur On the Safety Partner the OK status indicator flashes red The controller logs a Type 14 Code 12 minor fault that indicates that the controller i...

Страница 69: ...or gate switch It includes the added capability to initiate a functional test of the stop device It can monitor a feedback signal from a safety device and issue a lock request to a safety device DCST...

Страница 70: ...output and has a 500 ms inputs inconsistent timeout value ROUT Redundant Output Monitors the state of one input to control and monitor two outputs DIN Diverse Input Monitors two diverse safety inputs...

Страница 71: ...ion for a JMP instruction JSR Jump to Subroutine Jump to a separate routine RET Return Return the results of a subroutine SBR Subroutine Accept data that is passed to a subroutine by the JSR instructi...

Страница 72: ...motor or axis to detect movement of more than a defined amount in the unintended direction SBC Safe Brake Control The Safe Brake Control SBC instruction Controls safety outputs that actuate a brake Se...

Страница 73: ...SIL 3 Figure 20 on page 74 shows the steps that are required to create a safety Add On Instruction and then use that instruction in a safety application program The shaded items are steps unique to Ad...

Страница 74: ...Signature Go Off line Delete safety signature if it exists Return to original test project To Create a Safety Add On Instruction Create or Open a Project Create modify Application Export and Import th...

Страница 75: ...times be required for regulated industries Use it when your application calls for a higher level of integrity The instruction signature consists of an ID number and time stamp that identifies the cont...

Страница 76: ...instruction signature the name of the user the time stamp value and a user defined description Up to six history entries can be stored You must be offline to create a signature history entry Exportand...

Страница 77: ...ontinue with the validation of your application Test the Application Program This step consists of any combination of Run and Program mode online or offline program edits upload and download and infor...

Страница 78: ...78 Rockwell Automation Publication 1756 RM012B EN P April 2018 Appendix B Create and Use a Safety Add On Instruction Notes...

Страница 79: ...following equations determine the Connection Reaction Time Limit Input Connection Reaction Time Limit Input RPI x Timeout Multiplier Network Delay Multiplier Output Connection Reaction Time Limit Safe...

Страница 80: ...afety task period If the corresponding Connection Time Reaction Limit is not satisfactory you can adjust the safety task period via the Safety Task Properties dialog box See System Reaction Time on pa...

Страница 81: ...roduced consumed safety tags in the logic chain Simple Input logic output Chain This section describes the Logix system reaction time for any simple input to logic to output chain Figure 25 Logix Syst...

Страница 82: ...ed Consumed Safety Tags This section describes the Logix system reaction time for any input to controller A logic to controller B logic to output chain Figure 26 Logix System Reaction Time for Input t...

Страница 83: ...ultiplier Network Delay Multiplier The amount of network communication traffic 1 1 Network traffic and EMC create a lower limit for the values you can successfully use for Timeout Multiplier and Netwo...

Страница 84: ...tion Reaction Time Limits The following three values define the Connection Reaction Time Limit CRTL If you adjust these values then you can adjust the Connection Reaction Time Limit If a valid packet...

Страница 85: ...ur safety I O device and choose Properties 2 Click the Safety tab 3 Click Advanced to open the Advanced Connection Reaction Time Limit dialog box IMPORTANT The Timeout Multiplier and Network Delay Mul...

Страница 86: ...access the safety task period and watchdog time settings right click the Safety Task and choose Properties The priority of the safety task is not a safety concern as the safety task watchdog monitors...

Страница 87: ...fety tab click Advanced 5 You can view or edit the current settings in the Advanced dialog box See the following for more information ControlLogix 5580 and GuardLogix 5580 Controllers User Manual publ...

Страница 88: ...88 Rockwell Automation Publication 1756 RM012B EN P April 2018 Appendix C Reaction Times Notes...

Страница 89: ...be saved as a record of the plan The checklists on the following pages provide a sample of safety considerations and are not intended to be a complete list of items to verify Your particular safety ap...

Страница 90: ...he safety task rate period 4 Is the system response time in proper relation to the process safety time 5 Have probability PFD PFH values been calculated for each safety function 6 Have you performed a...

Страница 91: ...dLogix System Company Site Safety Function Definition SIL Input Channels Number Input Device Requirements Fulfilled Comment Yes No 1 Have you followed installation instructions and precautions to conf...

Страница 92: ...Checklist for GuardLogix System Company Site Safety Function Definition SIL Output Channels Number Output Device Requirements Fulfilled Comment Yes No 1 Have you followed installation instructions and...

Страница 93: ...andard tags 6 Are only safety tags used for safety routines 7 Have you verified that safety routines do not attempt to read from or write to standard tags 8 Have you verified that no safety tags are a...

Страница 94: ...94 Rockwell Automation Publication 1756 RM012B EN P April 2018 Appendix D Checklists for GuardLogix Safety Applications Notes...

Страница 95: ...dditional Resources on page 8 Useful Life The useful life of GuardLogix controllers is 20 years Safety Data For I O devices safety data including PFD and PFH values see the manuals for those products...

Страница 96: ...hr 7 24E 07 6 61E 07 7 33E 07 Dangerous Failure Rate D failures hr 7 10E 07 6 61E 07 7 33E 07 Dangerous Detected Failure Rate DD failures hr 7 10E 07 6 54E 07 7 26E 07 Dangerous Undetected Failure Rat...

Страница 97: ...of all output channels This approach reduces the amount of I O conditioning logic that is required and forces the logic to shut down all input or output channels on the affected module Use the Input F...

Страница 98: ...et inputs to safe state Example Rungs 2 and 3 Are the inputs used to drive safety application instructions Can Circuit Reset be used for operator intervention Is input fault information required for d...

Страница 99: ...ta 3 Node31InputsFaulted U Node31 I Pt00Data U Node31 I Pt01Data 4 Node30InputsFaulted L Node30 I Pt01Data L Node30 I Pt03Data U Node31 I Pt11Data Node 30 is an 8 point input 8 point output combinatio...

Страница 100: ...ulted L Node31Input01 L Node31Input03 Node31 I Pt00Data Node31Input00 Node31Input01 Node31Input11 Node31 I Pt01Data Node31 I Pt11Data Node 30 is an 8 point input 8 point output combination module Node...

Страница 101: ...o Write logic to set outputs to a safe state Example Rung 2 Write logic to unlatch output failure Example Rung 1 Write logic to latch output failure Example Rung 0 Done 0 Node30 I OutputStatus L Node3...

Страница 102: ...102 Rockwell Automation Publication 1756 RM012B EN P April 2018 Appendix F Studio 5000 Logix Designer Application Version 31 or Later Safety application Instructions Notes...

Страница 103: ...ed the ability to test untest or cancel the edits Average frequency of a dangerous failure PFH The probability of a system to have a dangerous failure occur per hour cancel edits Action that is taken...

Страница 104: ...en a task periodic or event is triggered while the task is still executing from the previous trigger partnership The primary controller and safety partner must both be present in SIL 3 and the hardwar...

Страница 105: ...se in safety related functions safety application instructions Safety Instructions that provide safety related functionality They have been certified to SIL 2 or SIL 3 for use in safety routines safet...

Страница 106: ...The safety task must be a periodic timed task safety task period The period at which the safety task executes safety task reaction time The sum of the safety task period plus the safety task watchdog...

Страница 107: ...order in which they are displayed in the controller organizer test edits Once online edits have been accepted there are two versions of user logic residing in controller memory The Test Edits command...

Страница 108: ...108 Rockwell Automation Publication 1756 RM012B EN P April 2018 Glossary Notes...

Страница 109: ...Safety protocol definition 106 clear fault 67 commissioning lifecycle 50 communication network 18 Compact GuardLogix controller 17 power supply 18 concept safety integrity level SIL 9 configuration s...

Страница 110: ...le delay time setting 84 GuardLogix chassis 16 control system safety I O 23 controller 15 controller system checklist 90 power supply 16 primary controller 16 safety application checklist 89 safety pa...

Страница 111: ...process 61 on delay function 24 online definition 104 online edit 58 60 process 61 out of box device SNN 35 output diagnostics 64 reaction time 24 safetyconnectionreactiontimelimit CRTL 84 output faul...

Страница 112: ...safety controller 37 safety data 95 safety function safety I O 23 specification 51 safety I O configuration signature 25 device replacement 26 GuardLogix control system 23 module 40 safety function 23...

Страница 113: ...ce 65 status data 24 status indicator 24 63 store project from memory card 57 Studio 5000 Logix Designer application safety application instruction 97 system de energize to trip 65 GuardLogix controll...

Страница 114: ...114 Rockwell Automation Publication 1756 RM012B EN P April 2018 Index...

Страница 115: ......

Страница 116: ...ineer http www rockwellautomation com global support direct dial page Literature Library Installation Instructions Manuals Brochures and Technical Data http www rockwellautomation com global literatur...

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