Allen-Bradley FlexLogix 1794 Manual de usuario

FLEXI/OSystemwithControlLogixforSIL2

Catalog Number Bulletin 1794

Reference Manual

AB Drives

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application,

Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at

http://literature.rockwellautomation.com) describes some important differences between solid state equipment and hard-wired electromechanical

devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this

equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this

equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated

with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and

diagrams.

No patent liability 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, RSLinx, RSLogix 5000 and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

WARNING

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may

lead to personal injury or death, property damage, or economic loss.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

ATTENTION

Identifies information about practices or circumstances that can lead to: personal injury or death, property damage, or

economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD

Labels may be on or inside the equipment, such as a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD

Labels may be on or inside the equipment, such as a drive or motor, to alert people that surfaces may reach dangerous

temperatures.

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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.

DC Diagnostic

Coverage The ratio of the detected failure rate to the total

failure rate.

EN 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.

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Preface 2

MTBF Mean Time

Between Failures Average time between failure occurrences.

MTTR Mean Time to

Restoration Average time needed to restore normal operation

after a failure has occurred.

PADT Programmingand

Debugging Tool RSLogix 5000 software used to program and

debug a SIL2-certified FLEX I/O with ControlLogix

application.

PC Personal

Computer Computer used to interface with, and control, a

ControlLogix system via RSLogix 5000

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 function.

1oo2 One out of two A 1oo2 (one out of two) architecture consists of

two channels connected in parallel such that

either channel can process the safety function.

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

Acronym: Full Term: Definition:

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Chapter

SIL Policy

This chapter introduces you to the SIL policy and how the

ControlLogix/FLEX I/O system meets the requirements for SIL2

certification.

Introduction to SIL

Certain catalog numbers (listed in Table 1.1 on page 1-5) of the FLEX I/O with

ControlLogix system are type-approved and certified for use in SIL2

applications, according to IEC 61508. SIL requirements are based on the

standards current at the time of certification.

These requirements consist of mean time between failures (MTBF),

probability of failure, failure rates, diagnostic coverage and safe failure

fractions that fulfill SIL2 criteria. The results make the ControlLogix/FLEX

I/O system suitable up to, and including, SIL2. When the

ControlLogix/FLEX I/O system 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 applications in which the

de-energized state is considered to be the safe state. All of the examples related

to I/O included in this manual are based on achieving de-energization as the

safe state for typical Emergency Shutdown (ESD) Systems.

For information about: See page:

Introduction to SIL 1-1

SIL2 Certification 1-2

Proof Tests 1-3

SIL2-Certified FLEX I/O System Components 1-5

Hardware Designs and Firmware Functions 1-8

Difference Between PFD and PFH 1-8

SIL Compliance Distribution and Weight 1-13

Response Times 1-13

AB Drives

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1-2 SIL Policy

SIL2 Certification

Figure 1.1 shows a typical SIL loop, including:

•the overall safety loop

•the ControlLogix/FLEX I/O portion of the overall safety loop

•how other devices (for example, HMI) connect to the loop, while

operating outside the loop

Figure 1.1

Plant-wide Ethernet/Serial

ControlNet

SIL2-certified ControlLogix components’ portion of the overall safety loop

Programming Software

For SIL applications, a programming

terminal is not normally connected.

HMI

For Diagnostics and Visualization (read-only access to controllers in the

safety loop). For more information, see publication 1756-RM001.

To other safety related

ControlLogix or FLEX I/O

remote I/O chassis

Overall Safety Loop

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 details.

Note 1: Multiple 1756-CNB or -CNBR modules can be installed into the chassis as needed.

Other configurations are possible as long as they are SIL2 approved.

Note 2: Two adapters are required for meeting SIL2 as shown in the figure.

The adapters can be either ControlNet or Ethernet and must be from the list of approved products.

Publication 1794-RM001G-EN-P - December 2011

SIL Policy 1-3

Proof Tests

IEC 61508 requires the user to perform various proof tests of the equipment

used in the system. Proof tests are performed at user-defined times (for

example, proof test intervals can be once a year, once every two years or

whatever timeframe is appropriate) and include some of the following tests:

•Testing of all fault routines to verify that process parameters are

monitored properly and the system reacts properly when a fault

condition arises.

•Testing of digital input or output channels to verify that they are not

stuck in the ON or OFF state.

IMPORTANT

Important Note related to published PFDs.

•The user must choose the appropriate PFD depending

on combinations and the appropriate 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 1oo1s is the sum of both.

IMPORTANT

The system user is responsible for:

•the set-up, SIL rating and validation of any sensors or

actuators connected to the ControlLogix/FLEX I/O

control system.

•project management and functional testing.

programming the application software and the module

configuration according to the description in the

following chapters.

The SIL2 portion of the certified system excludes the

development tools and display/human machine interface

(HMI) devices; these tools and devices are not part of the

run time control loop.

AB Drives

Publication 1794-RM001G-EN-P - December 2011

1-4 SIL Policy

•Calibration of analog input and output modules to verify that accurate

data is obtained from and used on the modules.

For more information on system proof tests, 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 must be recalculated.

Publication 1794-RM001G-EN-P - December 2011

SIL Policy 1-5

SIL2-Certified FLEX I/O

System Components

Table 1.1 lists the components available for use in a SIL2-certified FLEX I/O

system. For a list of ControlLogix SIL2 certified products, see publication

1756-RM001.

Table 1.1 FLEX I/O Components For Use in the SIL 2 System

Device Type: Catalog Number: (1) Description:

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