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Publication 1753-RM002C-EN-P - September 2008

15

Safety Concept for GuardPLC Controllers and GuardPLC I/O

Chapter

1

PFD and PFH Calculations

The average probability of a system to fail to satisfactorily perform its
safety function on demand is called Probability of Failure on Demand
(PFD). The probability of a system to have a dangerous failure occur
per hour is called Probability of Failure per Hour (PFH).

PFD and PFH calculations have been carried out for the GuardPLC
controllers and GuardPLC I/O system in accordance with IEC 61508.
For SIL 3, IEC 61508-1 sets the following minimum PFD and PFH
values:

PFD and PFH Values

Type

SIL 3 value per IEC 61508-1

PFD

10

-4

…10

-3

PFH

10

-8

…10

-7

per hour

GuardPLC Controllers

SIL-certified
Module IEC 61508

MTTF (in years)

PFD

PFH

GuardPLC 1200
Controllers

19.84

1.451664E-04

3.094950-E9

GuardPLC 1600
Controllers

17.69

4.158987E-05

3.926815E-09

GuardPLC 1800
Controllers

14.58

5.460105E-05

5.665043E-09

GuardPLC 2000

SIL-certified
Module IEC 61508

MTTF (in years)

PFD

PFH

Chassis

704.66

4.195800E-06

8.10000E-11

L1

44.03

4.884170E-05

4.36713E-09

IF8

73.12

1.746768E-05

4.14836E-09

HSC

45.33

5.993297E-05

3.28725E-09

IB24XOB16

34.28

3.710908E-05

1.09636E-09

Allen-Bradley Parts

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Содержание GuardPLC 1753

Страница 1: ...Safety Reference Manual Catalog Numbers 1753 1754 and 1755 GuardPLC Controller Systems Allen Bradley Parts...

Страница 2: ...ith 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 Automat...

Страница 3: ...s to this manual since the last publication To help you find new and updated information in this release of the manual we have included change bars as shown to the right of this paragraph We removed a...

Страница 4: ...4 Publication 1753 RM002C EN P September 2008 Summary of Changes...

Страница 5: ...GuardPLC Safety Input Modules 29 Safety of Sensors Encoders and Transmitters 29 Digital Inputs 29 Analog Inputs 33 Counter Module 36 Checklist for Safety Inputs 38 Chapter 4 GuardPLC Controller and Gu...

Страница 6: ...rs and I O Modules 75 Technical Safety for the Operating System 77 Operating Mode and Functions of the Operating System 77 Technical Safety for Programming 77 Parameters of the Automation System 80 Fo...

Страница 7: ...7 Table of Contents Appendix A Specifications Chapter Introduction 107 Climatic Conditions 108 Mechanical Conditions 108 EMC Conditions 109 Power Supply Conditions 110 Appendix B Use in Central Fire...

Страница 8: ...8 Publication 1753 RM002C EN P September 2008 Table of Contents...

Страница 9: ...ow the GuardPLC Control System including the GuardPLC controllers and distributed I O DeviceNet safety scanner and DeviceNet safety I O can be used in safety applications up to and including SIL 3 acc...

Страница 10: ...eck A number derived from and stored or transmitted with a block of data in order to detect corruption EN European Norm The official European Standard EPROM Erasable Programmable Read only Memory HSP...

Страница 11: ...UM001 Information on configuration and programming on DeviceNet networks for ArmorBlock and CompactBlock Guard Safety I O Modules GuardPLC Certified Function Blocks Basic Suite Safety Reference Manua...

Страница 12: ...12 Publication 1753 RM002C EN P September 2008 Preface...

Страница 13: ...0 controller with Modbus Communications 1753 L28BBBP GuardPLC 1600 controller with Profibus DP Communications 1753 L32BBBM 8A GuardPLC 1800 controller with Modbus Communications 1753 L32BBBP 8A GuardP...

Страница 14: ...ng Safety Integrated Level SIL 3 according to IEC 61508 and category 3 4 according to EN 954 1 Safety tests are based on the safety standards current at the time of certification These safety tests co...

Страница 15: ...n accordance with IEC 61508 For SIL 3 IEC 61508 1 sets the following minimum PFD and PFH values PFD and PFH Values Type SIL 3 value per IEC 61508 1 PFD 10 4 10 3 PFH 10 8 10 7 per hour GuardPLC Contro...

Страница 16: ...fety requirements including PFD and PFH for the DeviceNet Safety I O are in Chapter 6 GuardPLC I O SIL Certified Module IEC 61508 MTTF in years PFD PFH 1753 IB16 1 1 The PFD and PFH data is based on a...

Страница 17: ...ation safety Use RSNetWorx for DeviceNet software version 6 0 or later to configure the DeviceNet safety scanner and DeviceNet safety I O module Use RSLogix Guard PLUS programming software according t...

Страница 18: ...e time and the safety time Product Dependent You must use RSLogix Guard PLUS software to program the GuardPLC controller You must follow the guidelines listed on page 78 for initial startup or after a...

Страница 19: ...ure safe electrical isolation Your application should monitor the status bits associated with safety network connections Since connections often recover automatically make sure this occurrence does no...

Страница 20: ...in the process without a dangerous condition occurring If the fault condition lasts longer than the FTT the faulty signals can create a dangerous condition Safety Time of the PES The safety time is t...

Страница 21: ...witching times of the inputs and outputs must be taken into account When a network is used for communication data reaction times are affected Refer to Chapter 9 for reaction time calculations Watchdog...

Страница 22: ...22 Publication 1753 RM002C EN P September 2008 Chapter 1 Safety Concept for GuardPLC Controllers and GuardPLC I O Notes...

Страница 23: ...pply is required The GuardPLC 2000 controller is a modular system in which a power supply module a CPU module and up to 6 local I O modules comprise the system Power Supply Module The power supply tra...

Страница 24: ...ate in case of an error Flash EPROMs of the program memory for the operating system and application program suitable for a minimum of 100 000 programming cycles Data memory in SRAM Static RAM Multiple...

Страница 25: ...The operating system the application program the constants and parameters and the variable data are stored in every central processing unit in both processor sectors and are tested by a hardware compa...

Страница 26: ...GuardPLC Controllers and I O Modules Error Diagnostics Because the GuardPLC 1200 1600 and 1800 controllers are compact systems error diagnostics are summarized in a collective error LED indicator Each...

Страница 27: ...ction This chapter gives information about GuardPLC controllers and GuardPLC I O module input channels Topic Page Overview 28 General Information on GuardPLC Safety Input Modules 29 Safety of Sensors...

Страница 28: ...ontroller Digital Input 20 X GuardPLC 1800 Controller Digital Input 24 X 24 bit Counter 2 X Analog Input 8 X GuardPLC 16 point DC Input Module 1753 IB16 Digital Input 16 X GuardPLC 20 8 DC I O Module...

Страница 29: ...r failures in the module which do not affect the safety function user diagnostic information is not generated Safety of Sensors Encoders and Transmitters In a Safety application the sensors and the PE...

Страница 30: ...ed for the digital inputs in case of error See page 14 for an explanation of the closed circuit current system principle Reaction To Error If the test routines detect an error in digital inputs a 0 si...

Страница 31: ...ut are set to digital values by configuration of the operating points The test routines and safety functions of analog inputs explained on pages 33 36 also apply to the configurable digital inputs on...

Страница 32: ...and must be directly sequential Digital Input Monitoring The FAULT LED indicator on the front plate of the controller module flashes the inputs are set to 0 and an error code is generated when these...

Страница 33: ...e safety related accuracy is the guaranteed accuracy of the analog input without error reaction of the module This value should be taken into account when the safety functions are configured Input Val...

Страница 34: ...ulting value is not reliable The inputs must be terminated with a 10 K resistor parallel to the sensor The internal resistance of the source must be taken into account Input Values Number of Input Cha...

Страница 35: ...ram Reaction In Case of Fault If the test routines for analog inputs detect an error a 0 value is processed for the faulty channel in the application program and the FAULT LED indicator illuminates In...

Страница 36: ...channels General Depending on the parameters in the application program the counter can be operated as a fast up down counter with 24 bit resolution or as an encoder in the Gray code When used as a q...

Страница 37: ...oftware displays a decimal figure corresponding to the bit pattern Depending on the application this figure can be converted into BCD code Test Routines When the counter is operated as an encoder in t...

Страница 38: ...ty inputs It may be used as a planning draft as well as a proof If used as a planning draft the checklist can be saved as a record of the plan To ensure that the requirements are fully and clearly sat...

Страница 39: ...5 unipolar 0 10V DC unipolar 0 10V DC 1755 IF8 only 6 unipolar 0 20mA 7 bipolar 10V DC 1755 IF8 only 8 Is the voltage input terminated or programmed for application fault handling 9 Do the ranges of t...

Страница 40: ...40 Publication 1753 RM002C EN P September 2008 Chapter 3 GuardPLC Controller and GuardPLC I O Module Input Channels...

Страница 41: ...dPLC 2000 output modules Topic Page Overview of GuardPLC Output Modules 42 General Safety Information On GuardPLC Safety Outputs 42 Digital Outputs for Non relay Output Modules 43 Safety related 2 pol...

Страница 42: ...tion if an error occurs Output Capabilities Controller Module Type Quantity Safety Related Electrically Isolated GuardPLC 1200 Digital Output 8 X GuardPLC 1600 Controller Digital Output 8 X GuardPLC 1...

Страница 43: ...he GuardPLC 2000 System The illustration above does not represent the specifications of the related module Digital Outputs for Non relay Output Modules Non relay output modules have these types of dig...

Страница 44: ...shut down The total current draw of the module is monitored If the threshold is exceeded all channels of the output module are set to the Safety state 0 If an error occurs the output in accordance wi...

Страница 45: ...max of 200 s The minimum time between two tests is 20 seconds Monitor line at 2 pole connection short circuit to L L short circuit between 2 pole connections 1753 IB16XOB8 only line break in one of th...

Страница 46: ...a fault for EN 954 1 Cat 4 applications ATTENTION A short circuit between a negative switching output and L can cause a relay to switch on or another actuator to be switched into another operating st...

Страница 47: ...dicator External Short Circuit or Overload Performance If the output is short circuited to L L or an overload condition exists it is still possible to carry out tests on the module A safety shutdown i...

Страница 48: ...st the integrated redundant safety shutdown The operating voltage of the entire system is monitored de energizing all outputs at an undervoltage of 13V At the 1753 OW8 module the outputs are equipped...

Страница 49: ...ed in the application program There are also reactions to incorrect output values that must be specified Test Routines Both the safety switches for the shutdown of all four outputs of the module are a...

Страница 50: ...t in the event of failure Thus the safe condition is achieved at an output current of 0 mA and an output voltage of 0V DC In addition the respective channel status signals can be evaluated in the appl...

Страница 51: ...the FAULT LED indicator For the worst case reaction time of the analog outputs add double the watchdog time WDZCPU x 2 of the controller to double the watchdog time of the output module WDZAO C x 2 S...

Страница 52: ...Start up of Safety Manual GuardPLC Systems Company Site Loop definition Safety output channels in the GuardPLC 1200 GuardPLC 1800 GuardPLC 1600 GuardPLC 2000 No Requirements Fulfilled Comment Yes No 1...

Страница 53: ...Safety Protocol HSP The safety scanner supports standard DeviceNet Master and Slave connections as well as DeviceNet safety originator and target connections In addition there are the following essent...

Страница 54: ...rollers The DeviceNet safety scanner and GuardPLC controller interchange safety input and output data and standard input and output data tables Safety application data tables are protected from standa...

Страница 55: ...t are safety related Connect Signals Dialogs You must commission all safety devices with the MAC ID and communication rate if necessary before their installation on the safety network MAC ID and commu...

Страница 56: ...or Occurrence Time The occurrence time for multiple faults is the period of time in which the probability for the occurrence of multiple faults which in combination are critical to safety is sufficien...

Страница 57: ...tion was created The configuration signature is used in several operations During download from a configuration tool the configuration signature provides you with a means to check that the device and...

Страница 58: ...to precisely identify the intended target device during configuration and I O connection establishment Any device that originates a safety connection to another safety device must be configured with t...

Страница 59: ...testing is complete Complete these steps to guarantee safety 1 Assign SSN and configure devices using RSNetWorx for DeviceNet software 2 Read back and print out the configuration from the device 3 Com...

Страница 60: ...eNet software You are responsible for controlling access to the safety system including password use and handling After configuration data has been downloaded and verified the configuration data withi...

Страница 61: ...DeviceNet safety or standard connection errors do not cause the HSP connection to close and the associated status bit is set to one DeviceNet Connection Loss On the loss of a DeviceNet safety or stan...

Страница 62: ...753 UM002 for information on status and error codes Status Indicators The scanner has three status indicators that let you monitor module DeviceNet network and High speed Protocol HSP status The evalu...

Страница 63: ...in the safe state until a manual reset occurs This prevents unexpected output transitions from low to high when a connection recovers from a faulted or idle state DeviceNet Scanner Configuration Chec...

Страница 64: ...tion After adding one or more connections 4 Are the safety connection timing parameters suitable for the capacity of all CIP safety links traversed 5 Is the reaction time of each DeviceNet safety conn...

Страница 65: ...characteristics that do not require HSP retires for example default Controller Resend Timeout of 0 is acceptable Is the Controller Receive Timeout setting on the HSP Properties dialog in RSLogix Guard...

Страница 66: ...eater than twice the Watchdog Time Value 20 Is the Scanner Receive Timeout setting on the GuardPLC tab in RSNetWorx for DeviceNet equal to the WDZ time of the controller 21 Is the HSP connection estab...

Страница 67: ...onal Resources on page 11 Field safety I O modules can be connected to safety input and output devices allowing these devices to be controlled by a GuardPLC and DeviceNet safety scanner control system...

Страница 68: ...The DeviceNet safety I O modules should be used for applications that are in the safety state when the safety output turns OFF and the output data to the network turns OFF Diagnostics DeviceNet safet...

Страница 69: ...from a configuration tool the Configuration Signature provides you with a means to check that the device and the configuration tool agree on the information downloaded During connection establishment...

Страница 70: ...ne safety device already exists in the DeviceNet network configuration subsequent safety additions to that network configuration are assigned the same SNN as the lowest addressed safety device If no o...

Страница 71: ...t The scanner continuously attempts to reestablish the input connection Output Connection If an output connection is lost the connection is reported as faulted by the safety Scanner to the controller...

Страница 72: ...ock function with passwords is provided by the Safety Device Verification Wizard in RSNetWorx for DeviceNet software You are responsible for controlling access to the safety system including password...

Страница 73: ...the time from when an input signal is changed to when network data is sent The output reaction time is the time from when a network signal is received to when the state of output terminal is changed S...

Страница 74: ...llation instructions and precautions to conform to applicable safety standards Have you verified that the electrical specifications of the sensor and input are compatible Have you verified that the el...

Страница 75: ...n these three blocks Operating system Application program Programming tool RSLogix Guard PLUS software according to IEC 61131 3 The operating system is loaded in the central unit of the GuardPLC contr...

Страница 76: ...cation program are shown in the following table Operating System Functions Functions of the Operating System Connections to the Application Program Cyclical processing of the application program Acts...

Страница 77: ...ons of the Operating System The operating systems process the application program in cycles The following functions described in simplified form are executed Read input data Process logic functions pr...

Страница 78: ...te a suitable set of test cases covering the specification As a rule the independent test of each input and the important links from the application side should suffice RSLogix Guard PLUS software and...

Страница 79: ...ted rootcom config that indicates the overall configuration portion of the COM which is not safety related root config indicates the entire configuration including the remote I O modules CPU and COM 4...

Страница 80: ...bound to a certain requirement class However they must be available to the applicable approving board for every implementation of the automation system Operating Behavior Parameters Safety Parameter C...

Страница 81: ...he force system A Select All can be effected via the Force Editor in RSLogix Guard PLUS software All displayed signals should be verified in the controller All forced inputs or outputs can be reset by...

Страница 82: ...ramming software and PES is not necessary during RUN operation The requirements of the safety and application standards regarding the protection against manipulations must be observed The authorizatio...

Страница 83: ...ty signal source correction also via communication reach the user program Is each safety output signal correctly configured and is the output signal connected to a physical output channel After a Modi...

Страница 84: ...84 Publication 1753 RM002C EN P September 2008 Chapter 7 GuardPLC Controller Operating System...

Страница 85: ...or Windows 2000 operating system RSLogix Guard PLUS software contains these features Input function block editor monitoring and documentation Variables with symbolic names and variable types BOOL and...

Страница 86: ...be tested by the user and the PES can initiate safety operation Basis of Programming The application program should be easy to understand easy to trace easy to change easy to test The control task sh...

Страница 87: ...d circuit principle for digital sensors life zero for analog sensors Signals for error Determination of redundancies required for technical safety reasons 1oo2 2oo3 See the Safety of Sensors Encoders...

Страница 88: ...e and I O name should be the same The number of channels names per module depends on the type of module or system used The necessary diagnostic routines for safety I O modules or channels are automati...

Страница 89: ...g functional requirements may be used with the logic Appropriate logical and or arithmetic functions are used by the application program regardless of the closed circuit principle of the physical inpu...

Страница 90: ...tting for Safety Operation 1 1 The setting of the values only applies when you are online Main Enable The following switches parameters can be modified during operation of the programming software ON...

Страница 91: ...oading and starting you can modify the following switches in the controller in the following sequence a Start Restart allowed to FALSE and Loading allowed to FALSE b Main Enable to FALSE 1 The only di...

Страница 92: ...again See the Procedure for Locking the PES on page 91 Code Generation After input of the application program and completion of the I O assignments the code is generated forming the Configuration CRC...

Страница 93: ...elapsed or if forcing is stopped the signals being forced revert to control by the user program 1 The only distributed I O module that can be configured for forcing is 1753 IB20XOB8 ATTENTION Forcing...

Страница 94: ...The controller remains in the RUN state because the timeout was not reached and the Stop on Force Timeout switch was not set The force value is saved in the CPU If the CPU moves from RUN to STOP the...

Страница 95: ...Safety Data In the HSP Signal Connection dialogs in RSLogix Guard PLUS software signals that are transferred over safety connections are shown in white text on a red background Signals transferred ov...

Страница 96: ...96 Publication 1753 RM002C EN P September 2008 Chapter 8 Technical Safety for the Application Program...

Страница 97: ...Ethernet 98 High speed Safety Protocol 102 Reaction Times for DeviceNet Safety Communication 103 Available Options Controller GuardPLC 1200 GuardPLC 1600 GuardPLC 1800 GuardPLC 2000 1754 L28BBB 1753 L...

Страница 98: ...her and with the programming software via GuardPLC Ethernet network Monitoring of safety communication must be configured in the Peer to peer Editor by specifying the Receive Timeout ReceiveTMO If saf...

Страница 99: ...e TR The ReceiveTMO must be calculated and entered via the peer to peer editor If the communication partner does not receive a correct answer within the ReceiveTMO the safety related communication is...

Страница 100: ...st distributed I O module and the reaction of the outputs of the second distributed I O module can be calculated as follows TR input path output path where TR Worst Case Reaction Time input path t1 t2...

Страница 101: ...ceiveTMO t4 2 x WDZPES2 The Worst Case Reaction Time TR depends on the application and must be coordinated with the approving board TR can be read in the Worst Case column of the Peer to Peer Editor T...

Страница 102: ...and the DeviceNet safety scanner The HSP signature is calculated based on the layout of the device signals in RSNetWorx and is passed to RSLogix Guard PLUS software via the Scanner Signals File The H...

Страница 103: ...action of the outputs of the second DeviceNet Safety I O module can be calculated as follows TR input path output path where TR Worst Case Reaction Time input path tA tB tC output path tD tE tF WDZ Wa...

Страница 104: ...ation is A B C D E F System Reaction Time TR The 2 x WDT term is valid as long as the scanner s Scanner Receive Timeout is set to the same value as the controller s Watchdog Timeout System Reaction Ti...

Страница 105: ...eer Reaction Time The basic equation is A B C D System Reaction Time TR The 2 x WDT term is valid as long as the scanner s Scanner Receive Timeout is set to the same value as the controller s Watchdog...

Страница 106: ...106 Publication 1753 RM002C EN P September 2008 Chapter 9 Configuring Communication...

Страница 107: ...rotection Class II according to IEC EN61131 2 Pollution Degree II Altitude 2000 m IP20 Enclosure for Standard Applications An alternate enclosure may be required depending upon the standards relevant...

Страница 108: ...erature 40 85 C 40 185 F Battery only 30 C 22 F 6 3 4 2 Dry heat and cold resistance test 70 C 25 C 158 F 13 F 96h EUT Power supply unconnected 6 3 4 3 Change of temperature resistance and immunity te...

Страница 109: ...discharge 6 3 6 2 2 IEC EN61000 4 3 RFI test 10 V m 26MHz to 1GHz 80 AM 6 3 6 2 3 IEC EN61000 4 4 Burst tests 2 KV Power supply 1 KV Signal lines 6 3 6 2 4 IEC EN61000 4 12 Damped oscillatory wave imm...

Страница 110: ...wing standards IEC 61131 2 Safety Extra Low Voltage EN60950 SELV Protective Extra Low Voltage EN60742 PELV IEC EN 61131 2 Paragraph 6 3 7 Verification of DC Power Supply Characteristics 6 3 7 1 1 Volt...

Страница 111: ...y the required 1 second safety time error response time can also be achieved if necessary The fire alarms are connected using the open circuit principle with line control for the detection of short ci...

Страница 112: ...series connection of a zener diode protects the input over voltage in case of a short circuit For explicit line break monitoring at de energized outputs DO a transmitter supply to the analog inputs is...

Страница 113: ...pply Precautions must also be in place to guard against power supply failure Transition between the main and backup power supply must be without interruption Voltage dips of up to 10 ms are permitted...

Страница 114: ...114 Publication 1753 RM002C EN P September 2008 Appendix B Use in Central Fire Alarm Systems...

Страница 115: ...fety outputs 52 climatic conditions 108 closed circuit principle definition 14 code generation 92 communication DeviceNet safety 103 high speed 102 peer to peer 98 safety related 19 standard 98 102 co...

Страница 116: ...calculations 15 56 PFH calculations 15 56 power supply 23 power supply conditions 110 probability of failure on demand 15 probability of failure per hour 15 production rate 101 Proof Test Interval 56...

Страница 117: ...SFF 56 software GuardPLC 1200 2000 safety related systems 75 specifications climatic 108 EMC 109 mechanical 108 power supply 110 T technical safety application program 85 functions 89 general procedu...

Страница 118: ...118 Publication 1753 RM002C EN P September 2008 Index...

Страница 119: ...Allen Bradley Parts...

Страница 120: ...support rockwellautomation com Installation Assistance If you experience a problem within the first 24 hours of installation please review the information that s contained in this manual You can also...

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