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1794-RM001 - Rockwell Automation

1. V _ _ To other safety related ControlLogix or FLEX 1 0 See Figules 3 1 and 3 5 for details remote 1 0 chassis SIL2 certified ControlLogix components portion of the overall safety loop l r TRA FLEX TO es j Dn o eta ee l I Actuator I ControlNet To other safety related I I ControlLogix or FLEX 1 0 I l remote 1 0 chassis Input i Device I x DI2 poz TT sm HT Input I e Device I ControlNet l l l l I L i l 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 H Publication 1794 RM001 G EN P December 2011 Proof Tests SIL Policy 1 3 TAN Important Note related to published PFDs e The user must choose the appropriate PFD depending on combinations and the appropriate 1001 or 1002 configuration Descrete and analog inputs must be
2. Catalog Number Description MTBF x8 Estimated PFH 1oo2 1794 0E4 Analog Output Module 23 807 086 4 20E 08 2 96E 10 1794 0F4I Isolated Analog Output Module 7 191 128 1 39E 07 9 90E10 1794 OW8 Relay Output Module 14 766 876 6 77E 08 4 78E 10 1794 TB3 Terminal Base Units 21 128 3462 4 73E 08 3 3310 1794 TB3G Generic Terminal Base Units 27 320 800 3 66E 08 2 57E10 1794 TB3GS Generic Terminal Base Units 46 425 800 2 15E 08 1 51E10 1794 TB3S Terminal Base Unit 71 433 7470 1 40E 08 9 82E11 1794 TB3T Temperature Terminal Base Units 73 096 226 1 37E 08 9 59E11 1794 TB3TS Temperature Terminal Base Units 75 763 39912 1 32E 08 9 25E11 1794 TBN Terminal Base Units 75 716 615 1 32E 08 9 26E 11 1794 TBNF Fused Terminal Base Units 4 812 320 2 08E 07 1 49E09 1794 ACNR15XT ControlNet Redundant Media Adapter 8 223 684 1 22E 07 8 64E 10 1794 AENTRXT 10 100Mb Ethernet Redundant Communication Adapter 14268 0702 7 89E 07 6 05E 09 1794 OB8EPXT 8 Protected Output Module 14 771 049 6 77E 08 4 78E 10 1794 1B16XT 16 Sink Input Module 35 587 189 2 81E 08 1 87E 10 1794 0B16PXT 16 Protected Output Module 26 709 401 3 74E 08 2 63E 10 1794 IB10XOBBXT 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 47E 08 5 99E 10 1794 IE8XT 8 Input analog Module 14 041
3. Voltage Transmitter B Analog Input 1794 IF4l foo Lo EE EE 000000000000 OO OOOOOOOOOOOOO OO DDOOOOOOOOOOOOSO 1794 TB3 oltage Transmitter A 1794 IFAI Analog Input EE EE EE EE O00PHO00000000000 IDOQQOOOOOOOOOOOOO OODDOOOOOOOOOOOCO oltage Transmitter B 1794 TB3 Publication 1794 RM0016 EN P December 2011 3 10 HEXI 0 Modules Wiring the Single Ended Input Module in Current Mode In addition to following the General Considerations when using Any FLEX 1 0 Analog Input Module on page 3 7 before wiring the module consider the following application guideline e 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 1794 IE8 Analog Input Analog Input 1794 IE8 1794 IE8 OOOOOOOOOOOOOOO 001050000 000050000000005 1794 TB3 1794 TB3 Current RET Current RET Source A Source B Analog Input Analog Input 1794 IF4I 1794 IFAI OOOOOOOOOOOOOO O
4. Outputs OK A Timer MULT ADD SUB Range Delta Delta Tolerance Monitoring inputi Monitoring input Delta High Limit Low Limit LIM Low Limit CT Outputs 0K Output Echo High Limit Timer done C D Outputs Faulted Outputs Faulted The control diagnostics and alarming functions must be performed in sequence FLEX 1 0 Modules 3 15 e When wiring two analog output modules in the same application make sure Both modules use identical configuration The same controller owns both modules e Monitor the ControlNet status bits for the associated module and ensure that appropriate action is invoked via the application logic by these status bits Publication 1794 RM0016 EN P December 2011 3 16 HEXI 0 Modules Wiring FLEX 1 0 Analog Output Modules Publication 1794 RM001G EN P December 2011 In general good design practice dictates that each analog output must be wired to a separate input terminal to make 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 1794 0E4 1794 IE8 Analog Input Analog Output oar Module Module Isolated Analog Isolated Analog Output Module Input Module FLEX 1 0 Modules 3 17 Wir
5. 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 Publication 1794 RM0016 EN P December 2011 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 e how other devices for example HMI connect to the loop while operating outside the loop Figure 1 1 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 Plant wide Ethernet Serial lt Overall Safety Loop a m w s s s w w w w w s s s s m w m SK L6G
6. e Wire sensors to separate input points on two separate modules that are on different ControlNet nodes e Configuration parameters for example RPI filter values must be identical between the two modules e The same controller must own both modules e Monitor the ControlNet status bits for the associated module and ensure that appropriate action is invoked via the application logic by these status bits FLEX 1 0 Modules 3 3 Wiring FLEX 1 0 Digital Input Modules One Sensor Wiring Example Input 000000000000000Q COM 0000000000000001 O 24V OOOOOOOOOOOOOOO The wiring diagrams in Figure 3 1 show two methods of wiring the digital input Module In either case users must determine whether the use of 1 or 2 sensors is appropriate to fulfill SIL2 requirements Figure 3 1 ControlLogix Digital Input Module Wiring l 3 24V dc npu _ Optional relay contact Z to switch line voltage for periodic automated testing OOOOOOOOOOOOOOOG IOOOOOOOOOOOOOOOOO OOOOOOOOOOOOOOOO Two Sensor Wiring Example OOOOOOOOOOOOOOoO Input COM 24V OOoOooooooocoPoo 86686066080
7. 3 7 0E 06 1794 ACNR15XT ControlNet Redundant Media Adapter 8 223 684 1 22E 07 2 415E 06 1794 AENTRXT 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 1 45E 05 1794 OB8EPXT 8 Protected Output Module 14 771 049 6 77E 08 1 20E 06 1794 1B16XT 16 Sink Input Module 35 587 189 2 81E 08 4 95E 07 1794 0B16PXT 16 Protected Output Module 26 709 401 3 74E 08 6 60E 07 1794 IB10X0B6XT 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 IEAXOE2XT 4 Input 2 Output Analog Combo Module 11 800 802 8 47E 08 1 50E 06 1794 EBXT 8 Input analog Module 14 041 000 7 12E 08 1 26E 06 1794 OE4XT 4 Output Analog Module 11 381 744 8 79E 08 1 55E 06 1794 IF2XOF2IXT 2 Input 2 Output Isolated Analog Combo Module 6 317 918 1 58E 07 2 81E 06 1794 IFAIXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 2 43E 06 1794 F4ICFXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 2 43E 06 1794 0F4IXT 4 Isolated Output Analog Module 5 493 902 1 82E 07 3 24E 06 1794 1J2XT 2 Ch Frequency Counter Module 11 714 128 8 54E 08 1 51E 06 1794 IRT8XT 8 TC RTD Input Analog Module 8 204 792 1 22E 07 2 16E 06 MTEF measured in hours Calculated using field based values for components B 2 Failure Rate 1 MTBF Publication 1794 RM0016 EN P December 2011 1 10 SIL Policy Table 1 3 FLEX 1 0 Product Probability of Undetected Dangerous Failure per Hour PFH Calculat
8. 758E 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 0B16 16 Source Output Module 1 883 594 5 31E 07 9 62E 06 1794 0B16P Protected Output Module 2 135 280 4 68E 07 8 46E 06 H Publication 1794 RM001 G EN P December 2011 Table 1 2 FLEX 1 0 Product Probability of Failure on Demand PFD Calculations T 1 v SIL Policy 1 9 Catalog Number Description Mean Time A6 Calculated PFD Between Failure 1002 architecture MTBFJf 1794 OB8EP Protected Output Module 2 389 669 4 18E 07 7 54E 06 1794 0E4 Analog Output Module 23 807 086 4 20E 08 7 41E 07 1794 0F4I Isolated Analog Output Module 7 191 128 1 39E 07 2 47E 06 1794 OW8 Relay Output Module 14 766 876 6 77E 08 1 20E 06 1794 TB3 Terminal Base Units 21 128 346 4 73E 08 8 35E 07 1794 TB3G Generic Terminal Base Units 27 320 800 3 66E 08 6 45E 07 1794 TB3GS Generic Terminal Base Units 46 425 600 2 15E 08 3 79E 07 1794 TB3S Terminal Base Unit 71 433 747 1 40E 08 2 46E 07 1794 TB3T Temperature Terminal Base Units 73 096 226 1 37E 08 2 41E 07 1794 TB3TS Temperature Terminal Base Units 75 763 399 1 32E 08 2 32E 07 1794 TBN Terminal Base Units 75 716 615 1 32E 08 2 32E 07 1794 TBNF Fused Terminal Base Units 4 812 3200 2 08E 07
9. A 3 Estimated PFH 1002 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 691 134 1 45E 06 1 91E 08 lI 1794 AENTR 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 8 17E 09 1794 1B10X0B6 10 Input 6 Output Module 4 943 442 2 02E 07 1 59E 09 1794 1816 16 Sink Input Module 4 105 090 2 44E 07 1 96E 09 1794 IE8 Analog Input Module 37 952 679 2 63E 08 1 87E 10 1794 IF2X0F2I Isolated Analog Input Output Module 25 296 960 3 95E 08 2 83E 10 1794 IFAI Isolated Analog Input Module 11 746 343 8 51E 08 6 27E 10 1794 1J2 Frequency Counter Module 2 418 321 4 14E 07 3 62E 09 1794 IP4 Pulse Counter Module 2 375 360 4 21E 07 3 0E 09 1794 IR8 RTD Input Module 6 191 655 1 62E 07 1 24E 09 1794 IRT8 TC RTD mV Input Module 1 182 438 8 46E 07 8 97E 09 1794 IT8 Thermocouple Input Module 1 564 324 6 39E 07 6 22E 09 1794 0B16 16 Source Output Module 1 883 594 5 31E 07 4 92E 09 H Publication 1794 RM001 G EN P December 2011 Table A 6 MTBF Field Data and Per Module PFH Estimates T 5 years Failure Estimates A 9 Catalog Number Description MTBF x 3 Estimated PFH 1002 1794 0B16P Protected Output Module 2 135 280 4 68E 07 4 21E 09 1794 0B8EP Protected Output Module 2 389 6592 4 18E 07 3 6
10. 000 7 12E 08 5 03E 10 1794 0E4XT 4 Output Analog Module 11 381 744 8 79E 08 6 22E 10 1794 IF2XOF2IXT 2 Input 2 Output Isolated Analog Combo Module 6 317 918 1 58E 07 1 13E 09 1794 IFAIXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 9 75E 10 1794 IF4ICFXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 9 75E 10 1794 0F4IXT 4 Isolated Output Analog Module 5 493 902 1 82E 07 1 30E 09 1794 1J2XT 2 Ch Frequency Counter Module 11 714 128 8 54E 08 6 04E 10 1 MTBF measured in hours Calculated using field based values for components Failure Rate 1 MTBF H Publication 1794 RM001 G EN P December 2011 Failure Estimates A 7 Table A 5 MTBF Field Data and Per Module PFH Estimates T 2 years Catalog Number Description MTBF x8 Estimated PFH 1oo2 1794 ACN15 ControlNet Single Media Adapter 8 223 684 1 22E 07 8 76E 10 1794 ACNR15 ControlNet Redundant Media Adapter 8 223 684 1 22E 07 8 76E 10 1794 AENT 10 100Mb Ethernet Communication Adapter 691 134 1 45E 06 6 58E 09 1794 AENTR 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 6 58E 09 1794 IB10XOB6 10 Input 6 Output Module 4 943 442 2 02E 07 1 49E 09 1794 IB16 16 Sink Input Module 4 105 090 2 44E 07 1 81E 09 1794 IE8 Analog Input Module 37 952 679 2 63E 08 1 86E 10 1794 IF2X0F2I Isolated Analog Input Output Module 25 296 960 3 95E 08 2 79E 1
11. 05 1794 IE8 Analog Input Module 37 952 679 2 63E 08 2 33E 06 1794 IF2X0F2I Isolated Analog Input Output Module 25 296 960 3 95E 08 3 50E 06 1794 IFAI Isolated Analog Input Module 11 46 343 8 51E 08 7 64E 06 1794 1J2 Frequency Counter Module 2 418 321 4 14E 07 4 05E 05 1794 IP4 Pulse Counter Module 2 375 360 4 21E 07 4 13E 05 1794 IR8 RTD Input Module 6 191 655 1 62E 07 1 48E 05 1794 IRT8 TC RTD mV Input Module 1 182 438 8 46E 07 9 19E 05 1794 IT8 Thermocouple Input Module 1 564 324 6 39E 07 6 62E 05 1794 0B16 16 Source Output Module 1 883 594 5 31E 07 5 36E 05 1794 0B16P Protected Output Module 2 135 280 4 68E 07 4 65E 05 1794 0B8EP Protected Output Module 2 389 669 4 18E 07 4 10E 05 1794 0E4 Analog Output Module 23 807 086 4 20E 08 3 73E 06 1794 0HI 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 05E 06 1794 TB3 Terminal Base Units 21 128 34812 4 3E 08 4 21E 06 1794 TB3G Generic Terminal Base Units 27 320 800 3 66E 08 3 24E 06 1794 TB3GS Generic Terminal Base Units 46 425 600 2 15E 08 1 90E 06 1794 TB3S Terminal Base Unit 71 433 7472 1 40E 08 1 23E 06 1794 TB3T Temperature Terminal Base Units 73 096 226 1 37E 08 1 20E 06 1794 TB3TS Temperature Terminal Base Units 75 763 399 1 32E 08 1 16E 06 1794 TBN Terminal Base Units 75 716 615 1 32E 08 1 16E 06 1794 TBNF Fused Terminal Base Units 4 812 320 2 08E 07 1 93E 05 1794 ACNR15XT ControlNet Redundant Media Adapter 8 223 684 1 22E 07 1 1
12. IN039 1794 UM008 Module 1794 0E4 4 Output Analog Module NA 1794 IN100 1794 UM002 1794 0H4I 4 Isolated Output Analog A F G H l Lx 1794 IN037 1794 UM008 Module 1794 IT8 Thermocouple Input Module A K K x 1794 IN021 1794 UM007 1794 IR8 RTD Input Module A K K x 1794 IN021 1794 UM004 1794 IRT8 TC RTD Input Module B D E E 1 1794 IN050 1794 UM012 E x 1794 1J2 2 Ch Frequency Counter A D 1794 IN049 1794 UM011 Module 1794 IP4 4 Ch Pulse Counter Module B 4 4x 1794 IN064 1794 UM016 1 0 Modules 1794 IEAXOE2XT 4 Input 2 Output Analog B NA 1794 IN125 NA Analog Combo Module 1794 IE8XT 8 Input analog Module B NA 1794 OE4XT 4 Output Analog Module NA 1794 IF2XOF2IXT 2 Input 2 Output Isolated A I Lx 1794 IN129 Analog Combo Module 1794 IF4IXT 4 Isolated Input Analog A I 1 x Module 1794 0F4IXT 4 Isolated Output Analog A I Lx Module 1794 IFAICFXT 4 Isolated Input Analog A I Lx 1794 IN130 Module 1794 1J2XT 2 Ch Frequency Counter A E Ex 1794 IN049 Module 1794 IRT8XT 8 TC RTD Input Analog B D E E 1 E x 1794 IN050 Module H Publication 1794 RM001 G EN P December 2011 SIL Policy 1 7 Table 1 1 FLEX 1 0 Components For Use in the SIL 2 System Device Type Terminal Base Units versions M Certain catalog numbers have a K suffix This ind Unit Firmware Revision Catalog Number 1 Description Series 2 3 1794 TB3 3 Wire Terminal Base Unit
13. 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 analog input be calibrated at least every 3 years to verify the accuracy of the input signal and avoid nuisance application shutdowns Compare Analog Input Data and Annunciate Miscompares When wiring sensors to two inputs channels the values from those channels must be compared to each other for concurrence within an acceptable range for the application before actuating an output Any miscompate between the two inputs outside the programmed acceptable range must be annunciated as a fault In Figure 3 7 a user defined percentage of acceptable deviation that is tolerance is applied to the configured input range of the analog inputs that is range and the result is stored that is delta This delta value is then added to and subtracted from one of the input channels the results define an acceptable High and Low limit of deviation The second input channel is then compared to these limits to determine if the input are working properly Publication 1794 RM0016 EN P December 2011 3 8 FLEX 1 0 Modules Publication 1794 RM001G EN P December 2011 The inputs OK bit pr
14. hours Calculated using field based values for components B A Failure Rate 1 MTBF Table A 2 MTBF Field Data and Per Module PFD Estimates T 2 years Catalog Number Description MTBF A 3 Estimated PFD 1002 1794 ACN15 ControlNet Single Media Adapter 8 223 684 1 22E 07 4 33E 06 1794 ACNR15 ControlNet Redundant Media Adapter 8 223 684 1 22E 07 4 33E 06 1794 AENT 10 100Mb Ethernet Communication Adapter 691 134 1 45E 06 5 92E 05 1794 AENTR 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 3 02E 05 1794 1B10X0B6 10 Input 6 Output Module 4 943 442 2 02E 07 7 27E 06 1794 1B16 16 Sink Input Module 4 105 090 2 44E 07 8 79E 06 1794 IE8 Analog Input Module 37 952 679 2 63E 08 9 28E 07 1794 IF2X0F2I Isolated Analog Input Output Module 25 296 960 3 95E 08 1 39E 06 1794 F4l Isolated Analog Input Module 11 746 343 8 51E 08 3 02E 06 1794 1J2 Frequency Counter Module 2 418 321 4 14E 07 1 52E 05 1794 IP4 Pulse Counter Module 2 375 360 4 21E 07 1 55E U5 1794 IR8 RTD Input Module 6 191 655 1 62E 07 5 77E 06 1794 IRT8 TC RTD mV Input Module 1 182 438 8 46E 07 3 26E 05 H Publication 1794 RM001 G EN P December 2011 Table A 2 MTBF Field Data and Per Module PFD Estimates T 2 years Failure Estimates A 3 Catalog Number Description MTBF A 3 Estimated PFD 1002 1794 IT8 Thermocouple Input Module 1 564 324 6 39E 0
15. is the name given to the associated 1794 AVNR15 I This indicates the Input file ControlLogix Communications 2 3 SlotStatusBits This is a 32 bit value The lower 8 bits of this value are defined as follows for FLEX I O Module Module Module Module Module Module Module Module 7 6 5 4 3 2 1 0 Related Communications For more information on ControlLogix communications modules see the Modules Documentation following Rockwell Automation publications listed in Table 2 1 Table 2 1 Catalog Installation User Manual Number Description Instructions 1756 CNB ControlNet Communication 1756 IN571 CNET UM001 Module 1756 CNBR Redundant ControlNet Communication Module These publications are available from Rockwell Automation at http literature rockwellautomation com Publication 1794 RM001G EN P December 2011 24 ControlLogix Communications Publication 1794 RM0016 EN P December 2011 Chapter J Overview of FLEX 1 0 Modules FLEX 1 0 Modules This chapter discusses the FLEX I O modules that are SIL2 certified For information about See page Overview of FLEX 1 0 Modules 3 1 Using Digital Input Modules 3 2 Wiring FLEX 1 0 Digital Input Modules 3 3 General Considerations when using Any FLEX 3 4 1 0 Digital Output Module Wiring FLEX 1 0 Digital Output Modules 3 5 Using Analog Input Modules 3 7 Wiring FLEX 1 0 Analog Input Modules 398 Checklist for SIL Inpu
16. or start up an individual checklist can be filled in for every single SIL input channel in a system This is the only way to make sure that the requirements were fully and clearly implemented This checklist can also be used as documentation on the connection of external wiring to the application program Input Check List for ControlLogix FLEX 1 0 System Company Site Loop definition SIL input channels in the No All Input Module Requirements apply to both digital and analog input modules Yes No Comment 1 Is the RPI value set to an appropriate value for your application L 2 Are all modules owned by the same controller 3 Have you performed proof tests on the system and modules 4 Have you set up the fault routines L L 5 Are control diagnostics and alarming functions performed in sequence in application logic modules in their system are SIL2 certified Note The user must ensure that the hardware series and the firmware series and revision of the FLEX 1 0 6 Is the application logic monitoring one ControlNet status bit for the associated 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 L e The operational state is O
17. propagation delays See Table 1 1 for associated module information Each of the times listed above is variably dependent on factors such as the type of I O module and instructions used in the ladder program For examples of how to perform these calculations see publication 1756 RM001 Publication 1794 RM0016 EN P December 2011 1 14 SIL Policy Notes H Publication 1794 RM001 G EN P December 2011 ControlNet Bridge Module EtherNet IP Bridge Module Chapter 2 ControlLogix Communications This chapter discusses the communication modules used in a ControlLogix SIL2 system For information about See page ControlNet Bridge Module 2 1 EtherNet IP Bridge Module 2 1 Related Communications Modules 2 3 Documentation The ControlNet bridge modules 1756 CNB amp 1756 CNBR provide for the communications between ControlLogix and FLEX I O system ControlNet Cabling For remote racks 802 3 compliant shielded or unshielded twisted pair cable is required for EtherNet IP Although it is not a requirement 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 The EtherNet IP bridge modules 1756 ENBT 1756 EN2T 1756 EN2TR and 17
18. safety loop consisting of these products 3 70E 04 See Publication 1756 RM001 for more information Publication 1794 RM0016 EN P December 2011 1 12 SIL Policy 1794 ACNR15 1 1794 TB3 1 _ 1794 0B16 1794 IB16 am Ce LT 1756 1638 OOOOOOOOOOOOOOOO IOOOOOOOOOOOOOCOO 000000000000000 IOOOOOOOOOOOOOOOI ControlNet 1794 ACNR15 2 1794 TB3 2 x 1794 1B16 1794 OW8 r ita bo bla N 550555000050000 0000000000000000 0000000000000000 ControlNet H Publication 1794 RM001 G EN P December 2011 SIL Compliance Distribution and Weight Response Times SIL Policy 1 13 The programmable controller may conservatively be assumed to contribute 10 of the reliability burden A SIL 2 system may need to incorporate multiple inputs for critical sensors and input devices as well as dual outputs connected in series to dual actuators dependent on SIL assessments for the safety related system The response time of the system is defined as the amount of time it takes for a change in an input condition to be recognized and processed by the controllers 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 e I O and communication module RPI settings controller program scan times output module
19. state Publication 1794 RM0016 EN P December 2011 1 4 SIL Policy e Calibration of analog input and output modules to verify that accurate data is obtained from and used on the modules 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 For more information on system proof tests see Publication 1756 RM001 For more information on the necessary I O module see Table 1 1 H Publication 1794 RM001 G EN P December 2011 SIL2 Certified FLEX I 0 System Components SIL Policy 1 5 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 RMOO1 Table 1 1 FLEX 1 0 Components For Use in the SIL 2 System Device Type Adapter 1 0 Modules Digital Related Documentation with More Information on Catalog Number Firmware Installation User Manual Revision Instructions Catalog Number 1 Description Series 2 3 1794 ACN15 ControlNet Single Media C 43 1794 IN101 NA Adapter 5 1 5 2 5 3 5 X D 10 1 10 2 10 3 10 x 1794 ACNR15 ControlNet Redundant Medi
20. such as the adapter power supply e I O modules terminal base units and are covered in subsequent sections The ControlLogix FLEX 1 0 platform s designs features and characteristics make it one of the most intelligent platforms FLEX I O products evaluated by TUV Table 1 2 and Table 1 3 present values of the PFDs and PFHs for the specific FLEX I O uses the same PFD and PFH assumptions as stated in publication 1756 RMOO1 Table 1 2 FLEX 1 0 Product Probability of Failure on Demand PFD Calculations T 1 v Catalog Number Description Mean Time A6 Calculated PFD Between Failure 1002 architecture MTBFJf 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 6E 05 lI 1794 AENTR 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 1 45E 05 1794 1B10X0B6 10 Input 6 Output Module 4 943 442 2 02E 07 3 60E 06 1794 B16 16 Sink Input Module 4 105 090 2 44E 07 4 34E 06 1794 IE8 Analog Input Module 37 952 679 2 63E 08 4 64E 07 1794 IF2X0F2I Isolated Analog Input Output Module 25 296 960 3 95E 08 6 97E 07 1794 IFAI Isolated Analog Input Module 11 746 343 8 51E 08 1 50E 06 1794 1J2 Frequency Counter Module 2 418 321 4 14E 07 7 45E 06 1794 IP4 Pulse Counter Module 2 375 360 A21E 07
21. 0 1794 IFAI Isolated Analog Input Module 11 46 343 8 51E 08 6 08E 10 1794 1J2 Frequency Counter Module 2 418 321 4 14E 07 3 19E 09 1794 IP4 Pulse Counter Module 2 375 360 4 21E 07 3 25E 09 1794 IR8 RTD Input Module 6 191 655 1 62E 07 1 18E 09 1794 IRT8 TC RTD mV Input Module 1 182 438 8 46E 07 7 14E 09 1794 IT8 Thermocouple Input Module 1 564 324 6 39E 07 5 17E 09 1794 0B16 16 Source Output Module 1 883 594 5 31E 07 4 20E 09 1794 0B16P 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 0E4 Analog Output Module 23 807 086 4 20E 08 2 97E 10 1794 0F4I 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 1794 TB3 Terminal Base Units 21 128 346 4 73E 08 3 35E 10 1794 TB3G Generic Terminal Base Units 27 320 800 3 66E 08 2 59E 10 1794 TB3GS Generic Terminal Base Units 46 425 600 2 15E 08 1 52E 10 1794 TB3S Terminal Base Unit 71 433 7470 1 40E 08 9 83E 11 1794 TB3T Temperature Terminal Base Units 73 096 226 2 1 37E 08 9 61E 11 1794 TB3TS Temperature Terminal Base Units 75 763 39912 1 32E 08 9 27E116 1794 TBN Terminal Base Units 75 716 615 1 32E 08 9 27E 11 1794 TBNF Fused Terminal Base Units 4 812 320 2 08E 07 1 53E 09 1794 ACNR15XT ControlNet Redundant Media Adapter 8 223 684 1 22E 07 8 76E 10 1794 AENTRXT 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 6 58E 09 1794 OB8EPXT 8 Protected Output Modul
22. 0E 05 I 1794 AENTRXT 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 8 47E 05 1794 OB8EPXT 8 Protected Output Module 14 771 049 6 77E 08 6 05E 06 1794 1B16XT 16 Sink Input Module 35 587 189 2 81E 08 2 48E 06 1794 0B16PXT 16 Protected Output Module 26 709 401 3 74E 08 3 32E 06 H Publication 1794 RM001 G EN P December 2011 Table A 3 MTBF Field Data and Per Module PFD Estimates T 5 years Failure Estimates Catalog Number Description MTBF A8 Estimated PFD 1oo2 1794 IB10XOB6XT 10 Input 6 Output Combo Module 22 202 487 4 50E 08 4 00E 06 1794 0W8XT 8 Relay Output Module 18 518 519 5 40E 08 4 81E 06 1794 IEAXOE2XT 4 Input 2 Output Analog Combo Module 11 800 802 8 47E 08 7 61E 06 1794 IE8XT 8 Input analog Module 14 041 000 7 12E 08 6 37E 06 1794 OE4XT 4 Output Analog Module 11 381 744 8 79E 08 7 89E 06 1794 IF2XOF2IXT 2 Input 2 Output Isolated Analog Combo Module 6 317 918 1 58E 07 1 45E 05 1794 IF4IXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 1 25E 05 1794 IFAICFXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 1 25E 05 1794 0F4IXT 4 Isolated Output Analog Module 5 493 902 1 82E 07 1 68E 05 1794 1J2XT 2 Ch Frequency Counter Module 11 714 128 8 54E 08 7 87E 06 1794 IRT8XT 8 TC RTD Input Analog Module 8 204 792 1 22E 07 1 11E 05 1 MTBF measured in hours Calculated using field based values for
23. 10 1794 OW8 Relay Output Module 14 766 876 6 77E 08 4 78E 10 1794 TB3 Terminal Base Units 21 128 346 4 13E 08 3 33E 10 1794 TB3G Generic Terminal Base Units 27 320 800 3 66E 08 2 57E 10 1794 TB3GS Generic Terminal Base Units 46 425 600 2 15E 08 1 51E 10 1794 TB3S Terminal Base Unit 71 433 7470 1 40E 08 9 82E 11 1794 TB3T Temperature Terminal Base Units 73 096 22612 1 37E 08 9 59E11 1794 TB3TS Temperature Terminal Base Units 75 763 39912 1 32E 08 9 25E 11 1794 BN Terminal Base Units 75 716 615 1 32E 08 9 26E 11 1794 TBNF Fused Terminal Base Units 4 812 320 2 08E 07 1 49E 09 1794 ACNR15XT ControlNet Redundant Media Adapte 8 223 684 1 22E 07 8 64E 10 1794 AENTRXT 10 100Mb Ethernet Redundant Communication Adapter 1 268 0702 7 89E 07 6 05E 09 1794 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 0B16PXT 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 0W8XT 8 Relay Output Module 18 518 519 5 40E 08 3 80E 10 H Publication 1794 RM001 G EN P December 2011 SIL Policy 1 11 Table 1 3 FLEX 1 0 Product Probability of Undetected Dangerous Failure per Hour PFH Calculations T v Catalog Number Description Mean Time A6 Calculated PFH Between Failure 1002 architecture MTBF 1794 IEAXOE2XT 4 In
24. 3 5 ControlLogix FLEX 1 0 Standard Output Module Wiring Standard Digital Wire output point Standard Digital Output Module to input point to Input Module _ _ verify the correct COM 24V state of the output CO amalla kur e 0 12 345 67 8910111213115 o 12 34567 8910112131415 A OOOOOOOOOOOOOOQDO eee eee 60000000000000pP00 COM 66000000000000000 6000000000000400 24V de 2000000000000000 Output B Install a relay in position or B This relay is controlled by another output in the ControlLogix FLEX 1 0 system If a short circuit or fault occurs on output modules the relay can disconnect power to the modules An isolated relay output module 1794 DW8 can be used for 43363 this purpose when it is connected to a different 1794 ACN15 or ACNR15 ControlNet Adapter module Note Other configurations are possible as long they are SIL2 approved Application logic must be written to generate a fault in 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 b
25. 4 RM001G EN P December 2011 FLEX 1 0 Modules 3 19 Checklist for SIL Outputs The following checklist is required for planning programming and start up of SIL outputs It may be used as a planning guide as well as during proof testing If used as a planning guide the checklist can be saved as a record of the plan For programming or start up an individual requirement checklist must be filled in for every single SIL output channel in a system This is the only way to make sure that the requirements are fully and clearly implemented This checklist can also be used as documentation on the connection of external wiring to the application program Output Check List for ControlLogix FLEX 1 0 System Company Site Loop definition SIL output channels in the No All Output Module Requirements apply to both digital and analog output modules Yes No Comment 1 Have you performed proof tests on the modules L 2 s the RPI value set to an appropriate value for your application L 3 Have you set up fault routines including comparing output data with a corresponding input point 4 f required have you used external relays in your application to disconnect module power if a short or 7 other fault is detected on the module or isolated
26. 56 EN2TXT provide for the communications between ControlLogix and FLEX I O system Publication 1794 RM0016 EN P December 2011 2 2 ControlLogix Communications Module Fault Reporting for any FLEX 1 0 Module Publication 1794 RM001G EN P December 2011 EtherNet IP Cabling 802 3 compliant shielded or unshielded twisted pair cable is required for EtherNet IP EtherNet IP Module Diagnostic Coverage Communications over 10 100 MbpsNet media occur via CIP which guarantees delivery of the data All modules independently verify proper transmission of the data To monitor the connection status for this type of connection use a Get System Value GSV and an examination of MODULE objects 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 GSV AND Obtain MODULE Mask Off Lower 12 Object s Entry Status Bits of Value NEO Check Entry Status to make sure module is Fault gt running For more information on the GSV instruction monitor the SlotStatusBits for the Input tag of the associated adapter The lower 8 bits of this tag correspond to the associated slot For example the tag Node3 I SlotlStatusBits is defined as follows NODE3 This
27. 7 2 41E 05 1794 0B16 16 Source Output Module 1 883 594 5 31E 07 1 98E 05 1794 0B16P Protected Output Module 2 135 280 4 68E 07 1 73E 05 1794 0B8EP Protected Output Module 2 389 669 2 4 18E 07 1 54E 05 1794 0E4 Analog Output Module 23 807 086 4 20E 08 1 48E 06 1794 0F4I Isolated Analog Output Module 7 191 128 1 39E 07 4 96E 06 1794 0W8 Relay Output Module 14 766 876 6 77E 08 2 40E 06 1794 TB3 Terminal Base Units 21 128 346 4 73E 08 1 67E 06 1794 TB3G Generic Terminal Base Units 27 320 800 3 66E 08 1 29E 06 1794 TB3GS Generic Terminal Base Units 46 425 800 2 15E 08 7 58E 07 1794 TB3S Terminal Base Unit 71 433 747 2 1 40E 08 4 92E 07 1794 TB3T Temperature Terminal Base Units 73 096 226 1 3 E 08 4 81E 07 1794 TB3TS Temperature Terminal Base Units 7576833992 1 32E 08 4 64E 07 1794 TBN Terminal Base Units 75 716 615 1 32E 08 4 64E 07 1794 TBNF Fused Terminal Base Units 4 812 3200 2 08E 07 7 A7E 06 1794 ACNR15XT ControlNet Redundant Media Adapter 8 223 684 1 22E 07 4 33E 06 1794 AENTRXT 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 3 02E 05 1794 0B8EPXT 8 Protected Output Module 14 771 049 6 77E 08 2 40E 06 1794 1B16XT 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 18 518 519 5 40E 08 1 91E 06 1794 IEAXOE2XT 4 Input 2 Output Analog Combo Modul
28. 8E 09 1794 0E4 Analog Output Module 23 807 086 4 20E 08 3 02E 10 1794 0H4I Isolated Analog Output Module 7 191 128 1 39E 07 3 76E 10 1794 OW8 Relay Output Module 14 766 876 6 77E 08 4 94E 10 1794 TB3 Terminal Base Units 21 128 3460 4 73E 08 3 41E 10 1794 TB3G Generic Terminal Base Units 27 320 800 3 66E 08 2 62E 10 1794 TB3GS Generic Terminal Base Units 46 425 600 2 15E 08 1 53E 10 1794 TB3S Terminal Base Unit 71 433 747 1 40E 08 9 88E 11 1794 TB3T Temperature Terminal Base Units 73 096 226 1 37E 08 9 66E 11 1794 TB3TS Temperature Terminal Base Units 75 763 399 1 32E 08 9 31E 11 1794 TBN Terminal Base Units 75 716 615 1 32E 08 9 32E 11 1794 TBNF Fused Terminal Base Units 4 812 3200 2 08E 07 1 64E 09 1794 ACNR15XT ControlNet Redundant Media Adapter 8 223 684 1 22E 07 9 14E 10 1794 AENTRXT 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 8 17E 09 1794 0BBEPXT 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 0B16PXT 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 Analog Combo Module 11 800 802 8 47E 08 6 24E 10 1794 IE8XT 8 Input analog Module 14 041 000 7 12E 08 5 20E 10 1794 0E4XT 4 Output Analog Module 11 381 744 8 79E 08 6 48E 10 1794 IF2XOF2IXT 2 Input 2 Output Isolated Analog C
29. A NA 1794 TB3S 3 Wire Terminal Base Unit A NA 1794 TB3T Temperature Terminal Base A NA Unit 1794 TB3TS Spring clamp Temperature A NA Base Unit 1794 TB3G Cage clamp Gen Terminal A NA Base Unit 1794 TB3GS Spring clamp Gen Terminal A NA Base Unit 1794 TBN NEMA Terminal Base Unit NA 1794 TBNF Fused NEMA Terminal Base NA These publications are available from Rockwell Automation by visiting http literature rockwellautomation com Related Documentation with More Information on Catalog Number Installation Instructions 1794 IN092 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 ControlFlash User Manual NA icates a conformally coated version of the product These K versions have the same SIL2 certification as the non K 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 Publication 1794 RM0016 EN P December 2011 1 8 SI Policy Hardware Designs and Firmware Functions Difference Between PFD and PFH Diagnostic hardware designs and firmware functions designed into the ControlLogix FLEX I O platform allow it to achieve at least SIL2 certification in a single controller configuration These diagnostic features are incorporated into specific FLEX I O components
30. Ds cannot be wired in parallel without severely affecting their accuracy Two sensors must be used Figure 3 11 FLEX 1 0 Analog RTD Module Wiring RTD 1794 IR8 RTD 1794 IR8 Input Module Input Module OOOOOOOOOOOOOO 1794 TB3T 1794 TB3T OOOOOOOOOOOOOO 3 Wire RTD ermocouple nerm RTD mV RID m f Input Module 1794 IRT8 Input Module DESIRE 000000000000 2 2 OOOOOOOOOOOO O2OOOOOOOOOOOOOO 1794 TB3G f 000092000000000 1794 TB36 4 Wire RTD Note 2 3 or 4 wire RTDs can be used as applicable to the associated RTD input module Publication 1794 RM0016 EN P December 2011 Using Analog Output Modules FLEX 1 0 Modules 3 13 General Considerations when using Any FLEX 1 0 Analog Output Module There are a number of general application considerations that you must follow when applying the analog output modules in a SIL2 application Proof Tests Periodically for example once every several years a System Validation test must be performed Manually of automatically test outputs to make sure that all outputs are operational Channel data should be varied over the full operating range to make sure that the corresponding field signal levels vary accordingly For additional information on see Publication 1756 RM001 Calibrate Outputs Periodically As Necessary FLEX I O modules ship from the factory with a high
31. FLEX I O System with ControlLogix for SIL 2 Allen Bradley Catalog Number Bulletin 1794 Reference Manual Rockwell Allen Bradley Rockwell Software Automation 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 de
32. Input Module Zex7Z voc sm meur reesei O 0 12 345 67 8910112131415 5000000000000000 OOOOOOOOOOOOOOOO 43364 Using Analog Input Modules FLEX 1 0 Modules 3 7 General Considerations when using Any FLEX 1 0 Analog Input Module There are a number of general application considerations that you must follow when applying these modules in a SIL2 application Proof Tests Periodically for example once every several years a System Validation test must be performed Manually of automatically test inputs to make sure that all inputs are operational Field signal levels should be varied over the full operating range to make sure that the corresponding channel data varies accordingly For additional information refer to publication 1756 RMO001 Calibrate Inputs Periodically As Necessary FLEX I O modules ship from the factory with a highly accurate level of calibration However because each application is different users are responsible for making sure their FLEX I O modules are 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 input module needs to be recalibrated a user can determine a tolerance band of accuracy
33. N e The non operational state is OFF e Both modules are owned by the same controller e Sensors are wired to separate input points e Configuration parameters for example RPI filter values are identical e Both input modules are on different ControlNet nodes 2 For the standard input modules is the Communication Format set to one of the Input Data choices L No Additional Analog Input Module 0nly Requirements Yes No Comment 1 Have you calibrated the modules as often as required by your application L 2 Are you using ladder logic to compare the analog input data on two channels to make sure there is r concurrence within an acceptable range and that redundant data is used properly 3 Have you written application logic to examine bits for any condition that may cause a fault and appropriate fault routines to handle the fault condition 4 When wiring the FLEX 1 0 analog module in voltage mode are transmitter connections wired correctly L 5 When wiring the FLEX 1 0 analog module in current mode are loop devices placed properly 6 When wiring FLEX 1 0 thermocouple modules in parallel have you wired to the same channel on each module 7 When wiring two FLEX 1 0 RTD modules are two sensors used mil 8 When two analog inputs are wired in the same application are both modules on different ControlNet Nodes L Publication 179
34. N to OFF or OFF to ON For additional information refer to publication 1756 RM001 Figure 3 4 Application Logic Output Fault 5 Output Bit Monitoring Input A Output Bit Monitoring Input L Timer done Fault O Alarm to Operator 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 energize users must wire an external method that can remove power from the actuator if a short or other fault is detected Test outputs at specific times to make sure they are operating properly The method and frequency of testing is determined by the type of module Publication 1794 RM001G EN P December 2011 FLEX 1 0 Modules 3 5 Monitor the ControlNet status bits for the associated module and ensure that appropriate action is invoked via the application logic by these status bits Wiring FLEX 1 0 Digital Standard Digital Output Modules Output Modules When using standard output modules users must wire an output to an actuator and then back to an input to monitor the output s performance In addition to following the General Considerations when using Any FLEX 1 0 Digital Output Module on page 3 4 the user must wire each standard output to a corresponding input to validate that the output is following its commanded state Figure
35. OOOOOOOOOOOOO 000000000000000 000000000000000 O 1794 TB3 1794 TB3 Current RET Current RET Source A Source B Publication 1794 RM001G EN P December 2011 FLEX 1 0 Modules 3 11 Wiring the Thermocouple Input Module In addition to following the General Considerations when using Any FLEX 1 0 Analog Input Module on page 3 7 before wiring the module consider the following application guideline e 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 1 0 Analog Thermocouple Module Wiring ermocoupie ermocouple Input Module 1794 18 Input Module 134g OOOOOOOOOQOPDOOO OOOOOOOOOODOOO 2IIOOOOOOOOOOPOOCGO 1794 TB3T 2IIOOOOOOOOOOPOOCGO 1794 TB3T po OOOOQOQDOOO po OOOOdOO CO date s sa sg RTD mV 1794 IRT8 RTD mV 1794 IRT8 Input Module Input Module O2OOOOOOOOOO Si O2OOOOOOOOOO 1794 TB3G D0200000000p0000 1 94 IB36 OOO OOOOOOO OOOO OOO e OOO OOO OOO O Publication 1794 RM001G EN P December 2011 3 12 HEXI 0 Modules Wiring the RTD Input Module In addition to following the General Considerations when using Any FLEX 1 0 Analog Input Module on page 3 7 before wiring the module consider the following application guideline e RT
36. States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 1794 RM0016 EN P December 2011 Supersedes Publication 1794 RM001F EN P September 2011 Copyright 2011 Rockwell Automation Inc All rights reserved Printed in the U S A
37. Term Definition CIP Control and A messaging protocol used by Logix5000 Information systems It is a native communications protocol Protocol used on ControlNet communications networks among others DC Diagnostic The ratio of the detected failure rate to the total Coverage 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 Publication 1794 RM0016 EN P December 2011 Preface 2 Publication 1794 RM0016 EN P December 2011 Table Preface 2 List of Acronyms Used Throughout the Safety Application Manual Acronym Full Term Definition MIBF Mean Time Average time between failure occurrences Between Failures MITR Mean Time to Average time needed to restore normal operation Restoration after a failure has occurred PADT Programming and RSLogix 5000 software used to program and Debugging Tool debug a SIL2 certified FLEX 1 0 with ControlLogix application PC Personal Computer used to interface with and control a Computer ControlLogix system via RSLogix 5000 programming software PFD Probability of The average probability of a system to fail to Failure on perform its design function on demand Demand PFH Probability of The probability of a system to have a dangerous Failure per Hour failure occur per hour 1001 One out of one A 1001
38. a C 43 Adapter 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 1794 IN128 5 X D 10 1 10 2 10 3 10 x 1794 AENT 10 100Mb Ethernet B 4 1 1794 IN082 Communication Adapter 4 2 4 X 1794 AENTR A 1 011 1 x 1794 IN131 1794 UM066 1794 AENTRXT 1794 IB16 16 Sink Input Module A NA 1794 IN093 NA 1794 IB10XOB6 10 Input 6 Output Module A NA 1794 IN083 1794 0816 16 Source Output Module A NA 1794 IN094 1794 0B16P 16 Protected Output Module A NA 1794 IN094 1794 0BBEP 8 Protected 0utput Module A NA 1794 IN094 1794 0W8 Isolated Relay Output Module A NA 1794 IN019 1794 OB8EPXT 8 Protected Output Module A NA 1794 IN124 1794 IB16XT 16 Sink Input Module A NA 1794 0B16PXT 16 Protected Output Module A NA 1794 IB10XOB6XT 10 Input 6 Output Combo A NA Module 1794 OW8XT 8 Relay Output Module A NA 1794 IN019 Publication 1794 RM001G EN P December 2011 1 6 SI Policy Table 1 1 FLEX 1 0 Components For Use in the SIL 2 System Related Documentation with More Information on Catalog Number Firmware Installation User Manual Revision Instructions Device Type Catalog Number 1 Description Series 2 3 1 0 Modules 1794 E8 8 Input Analog Module B NA 1794 IN100 1794 UM002 h ng 1794 IF4I 4 Isolated Input Analog A F 6 H I Ix 1794 IN038 1794 UM008 Module 1794 IF2X0F2I 2 In 2 Out Isolated Combo A F G H l Lx 1794
39. components B A Failure Rate 1 MTBF Table A 4 MTBF Field Data and Per Module PFH Estimates T 1 year Catalog Number Description MTBF x8 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 Communication Adapter 1 268 970 2 7 89E 07 6 05E 09 1794 1B10X0B6 10 Input 6 Output Module 4 943 442 2 02E 07 1 45E09 1794 1B16 16 Sink Input Module 4 105 090 2 44E 07 1 76E 09 1794 IE8 Analog Input Module 37 952 679 2 63E 08 1 85E 10 1794 IF2X0F2I Isolated Analog Input Output Module 25 296 960 3 95E 08 2 78E 10 1794 IF4I Isolated Analog Input Module 11 746 343 8 51E 08 6 02E 10 1794 1J2 Frequency Counter Module 2 418 321 4 14E 07 3 04E09 1794 IP4 Pulse Counter Module 2 375 360 4 21E 07 3 10E09 1794 IR8 RTD Input Module 6 191 655 1 62E 07 1 15E 09 1794 IRT8 TC RTD mV Input Module 1 182 438 8 46E 07 6 53E 09 1794 IT8 Thermocouple Input Module 1 564 324 6 39E 07 4 82E 09 1794 0B16 16 Source Output Module 1 883 594 5 31E 07 3 96E 09 1794 0B16P Protected Output Module 2 135 280 4 68E 07 3 47E09 1794 OB8EP Protected Output Module 2 389 669 2 4 18E 07 3 08E09 Publication 1794 RM0016 EN P December 2011 A 6 Failure Estimates Table A 4 MTBF Field Data and Per Module PFH Estimates T 1 year
40. d66 Note 1 Both sensors EJ I 43366 are monitoring he same safety applicatI 0000000000000000 00000000000000000 0000000000000000 43366 Application logic can compare input values or states for concurrence Figure 3 2 Input B The user program must also contain rungs to annunciate a fault in the event of Input A a sustained miscompare between two points Figure 3 3 nput A Input B CTimer nput Input B Timer preset in milliseconds to compensate for filter time and L hardware delay differences Timer Done TaD Fault Alarm to Operator Publication 1794 RM0016 EN P December 2011 3 4 FLEX 1 0 Modules The control diagnostics and alarming functions must be performed in sequence For more information on faults see publication 1756 RM001 General Considerations when using Any FLEX 1 0 Digital Output Module Regardless of the type of FLEX I O output module used there are a number of general application considerations that you must follow when applying these modules in a SIL2 application Proof Tests Periodically for example once every several years a System Validation test must be performed Manually of automatically test outputs to make sure that all outputs are operational and not stuck in the ON or OFF state Outputs must be cycled from O
41. dia Adapter 8 223 684 1 22E 07 2 15E 06 Publication 1794 RM0016 EN P December 2011 A 2 Failure Estimates Table A 1 MTBF Field Data and Per Module PFD Estimates T 1 year Catalog Number Description MTBF x8 Estimated PFD 1002 I 1794 AENTRXT 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 1 45E 05 1794 0BBEPXT 8 Protected Output Module 14 771 049 6 77E 08 1 20E 06 1794 1B16XT 16 Sink Input Module 35 587 189 2 81E 08 4 95E 07 1794 0B16PXT 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 IEAXOE2XT 4 Input 2 Output Analog Combo Module 11 800 802 8 47E 08 1 50E 06 1794 IE8XT 8 Input analog Module 14 041 000 7 12E 08 1 26E 06 1794 0E4XT 4 Output Analog Module 11 381 744 8 79E 08 1 55E 06 1794 IF2XOF2IXT 2 Input 2 Output Isolated Analog Combo Module 6 317 918 1 58E 07 2 81E 06 1794 IFAIXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 2 43E 06 1794 IF4ICFXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 2 43E 06 1794 0F4IXT 4 Isolated Output Analog Module 5 493 902 1 82E 07 3 24E 06 1794 1J2XT 2 Ch Frequency Counter Module 11 714 128 8 54E 08 1 51E 06 1794 IRTBXT 8 TC RTD Input Analog Module 8 204 792 1 22E 07 2 16E 06 MTBF measured in
42. e 11 800 802 8 47E 08 3 00E 06 1794 IE8XT 8 Input analog Module 14 041 000 7 12E 08 2 52E 06 1794 OE4XT 4 Output Analog Module 11 381 744 8 79E 08 3 12E 06 1794 IF2XOF2IXT 2 Input 2 Output Isolated Analog Combo Module 6 317 918 1 58E 07 5 66E 06 1794 IF4IXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 4 89E 06 1794 IFAICFXT 4 Isolated Input Analog Module 7 297 140 1 3 E 07 4 89E 06 1794 0F4IXT 4 Isolated Output Analog Module 5 493 902 1 82E 07 6 52E 06 1794 1J2XT 2 Ch Frequency Counter Module 11 714 128 8 54E 08 3 03E 06 1794 IRTBXT 8 TC RTD Input Analog Module 8 204 792 1 22E 07 4 34E 06 1 MTBF measured in hours Calculated using field based values for components Failure Rate 1 MTB Publication 1794 RM0016 EN P December 2011 A 4 Failure Estimates Table A 3 MTBF Field Data and Per Module PFD Estimates T 5 years Catalog Number Description MTBF x8 Estimated PFD 1oo2 1794 ACN15 ControlNet Single Media Adapter 8 223 684 1 22E 07 1 10E 05 1794 ACNR15 ControlNet Redundant Media Adapter 8 223 684 1 22E 07 1 10E 05 1794 AENT 10 100MD Ethernet Communication Adapter 691 134 1 45E 06 1 79E 04 lI 1794 AENTR 10 100MD Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 8 47E 05 1794 1B10X0B6 10 Input 6 Output Module 4 943 442 2 02E 07 1 88E 05 1794 B16 16 Sink Input Module 4 105 090 2 44E 07 2 28E
43. e 14 771 049 6 77E 08 4 82E 10 1794 IB16XT 16 Sink Input Module 35 587 189 2 81E 08 1 98E 10 1794 0B16PXT 16 Protected Output Module 26 709 401 3 74E 08 2 64E 10 Publication 1794 RM0016 EN P December 2011 A 8 Failure Estimates Table A 5 MTBF Field Data and Per Module PFH Estimates T 2 years Catalog Number Description MTBF 3 Estimated PFH 1002 1794 IB10X0B6XT 10 Input 6 Output Combo Module 22 202 487 4 50E 08 3 19E 10 1794 0W8XT 8 Relay Output Module 18 518 519 5 40E 08 3 83E 10 1794 IE4XOE2XT 4 Input 2 Output Analog Combo Module 11 800 802 8 4 E 08 6 05E 10 1794 IE8XT 8 Input analog Module 14 041 000 7 12E 08 5 07E 10 1794 OE4XT 4 Output Analog Module 11 381 744 8 79E 08 6 28E 10 1794 IF2XOF2IXT 2 Input 2 Output Isolated Analog Combo Module 6 317 918 1 58E 07 1 15E 09 1794 IF4IXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 9 91E 10 1794 IF4ICFXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 9 91E 10 1794 0F4IXT 4 Isolated Output Analog Module 5 493 902 1 82E 07 1 33E 09 1794 1J2XT 2 Ch Frequency Counter Module 11 714 128 8 54E 08 6 10E 10 1794 IRT8XT 8 TC RTD Input Analog Module 8 204 792 1 22E 07 8 79E 10 1 MTBF measured in hours 2 Calculated using field based values for components 6 A Failure Rate 1 MTBF Table A 6 MTBF Field Data and Per Module PFH Estimates T 5 years Catalog Number Description MTBF
44. e performed in sequence Publication 1794 RM0016 EN P December 2011 3 6 FLEX 1 0 Modules Users can also wire a standard digital output module in series with an isolated relay output module in series with a critical actuator In the event that a failure is detected the output from both output modules must be set to OFF to guarantee the Output Loads de energize This is shown in Figure 3 6 Figure 3 6 ControlLogix FLEX 1 0 Standard Output Module Wiring With an Isolated Relay Module Standard Digital Output Module 24V mmay COM ext SOURCE OUTPUT 0 12 345 67 8910112131415 Emaan OOOOOOOOOOOOOOOO Isola Outpu ed Relay Module Flexo 1794 0816 0 12 345 67 8910111213141 Emaan SQOOOOOOOOOOOOOO OOOOOOOOOOOooocce 0000000000000000 4000000000000000 DOOOOOOOOOOCOCO Note 1 An external relay can be replaced with an isolated relay module which is mounted in another FLEX 1 0 rail Publication 1794 RM0016 EN P December 2011 Wire output point to input point to verify the correct state of the output Standard Digital
45. econditions a Timer run that is preset to accommodate an acceptable fault response time and any communication filtering lags in the system If the inputs miscompare for longer than the preset value a fault is registered with a corresponding alarm Figure 3 7 Inputs OK L Timer MULT ADD SUB Range Delta Delta Tolerance Input 1 Input 1 Delta High Limit Low Limit LIM Low Limit CD Inputs OK Input 2 High Limit Timer done D Inputs Faulted Inputs Faulted C Alarm to Operator The control diagnostics and alarming functions must be performed in sequence Configuration parameters for example RPI filter values must be identical between the two modules e The same controller must own both modules e 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 ControlNet nodes FLEX 1 0 Modules 3 9 Wiring FLEX 1 0 Analog Input Modules Figure 3 8 ControlLogix Analog Input Module Wiring One Sensor Wiring Example The wiring diagrams in show two methods of wiring the analog input Module In either case users
46. es Notes Publication 1794 RM001G EN P December 2011 Chapter 4 General Requirements for Application Software Refer to publication 1756 RM001 Using ControlLogix in SIL2 Applications Publication 1794 RM001G EN P December 2011 4 2 General Requirements for Application Software Notes Publication 1794 RM0016 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 Publication 1794 RM0016 EN P December 2011 5 2 Technical SIL2 Requirements for the Application Program Notes Publication 1794 RM0016 EN P December 2011 Appendix A Failure Estimates The following tables list the failure estimates for the FLEX I O products included in this manual for different proof test intervals Table A 1 MTBF Field Data and Per Module PFD Estimates T 1 year Catalog Number Description imwa A EstimatedPFD 1002 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 6E 05 1794 AENTR 10 100Mb Ethernet Redundant Communication Adapter 1 268 070 7 89E 07 1 45E 05 1794 1B10X0B6 10 Input 6 Output Module 4 943 442 2 02E 07 3 60E 06 1794 B16 16 Sink Inp
47. ing the Analog Output Module in Current Mode In addition to following the General Considerations when using Any FLEX I O Analog Output Module on page 3 13 consider the following application guideline before wiring the module in current mode e 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 0E4 1794 IE8 SSS Analog Input Module Analog Output PQOOOOOOOOOOO00C OOOOOOOOOOOOOOO EA E ole lolol oe oe Poo Toe Too Toe Too To oe oe pooooocoooooooooo 0000000000000000 md 1794 TB3 OOOOOOOOOOO ST 1794 183 nh OO 1794 IF4l SSS SS Isolated Analog Output Module Isolated Analog Input Module ETIESIESEESE E E E OOOOOOOOOOOOOGOI 1794 TB3 EST 12218 Publication 1794 RM001G EN P December 2011 3 18 FLEX 1 0 Modules Checklist for SIL Inputs The following checklist is required for planning programming and start up of SIL inputs It may be used as a planning guide as well as during proof testing If used as a planning guide the checklist can be saved as a record of the plan For programming
48. ions T v Catalog Number Description Mean Time A6 Calculated PFH Between Failure 1002 architecture MTBF 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 Communication Adapter 1 268 0702 7 89E 07 6 05E 09 1794 IB10XOB6 10 Input 6 Output Module 4 943 442 2 02E 07 1 45E 09 1794 IB16 16 Sink Input Module 4 105 090 2 44E 07 1 6E 09 1794 IE8 Analog Input Module 37 952 679 2 63E 08 1 85E 10 1794 IF2X0F2I Isolated Analog Input Output Module 25 296 960 3 95E 08 2 78E 10 1794 IF4 Isolated Analog Input Module 11 746 343 8 51E 08 6 02E 10 1794 1J2 Frequency Counter Module 2 418 321 4 14E 07 3 04E 09 1794 IP4 Pulse Counter Module 2 375 360 4 21 E 07 3 10E 09 1794 IR8 RTD Input Module 6 191 655 1 62E 07 1 15E 09 1794 IRT8 TC RTD mV Input Module 1 182 438 8 46E 07 6 53E 09 1794 IT8 Thermocouple Input Module 1 564 324 6 39E 07 4 82E 09 1794 0B16 16 Source Output Module 1 883 594 5 31E 07 3 96E 09 1794 0B16P Protected Output Module 2 135 280 4 68E 07 3 47E 09 1794 OB8EP Protected Output Module 2 389 669 4 18E 07 3 08E 09 1794 0E4 Analog Output Module 23 807 086 4 20E 08 2 96E 10 1794 OF4l Isolated Analog Output Module 7 191 128 1 39E 07 9 90E
49. ital 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 Index 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 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 Calculations for each catalog number 1 8 Definition Preface 2 Probability of failure per hour PFH 1 8 1 11 Calculations for each catalog number 1 10 Definition Preface 2 Proof tests 1 3 3 2 3 4 3 7 3 13 RSLogix 5000 Preface 2 General requirements 4 1 S SIL compliance Distribution and weight 1 13 SIL loop example 1 2 SIL2 requirements For the application program 5 1 SIL2 certified components Complete list of ControlLogix catalog numbers 1 5 Software General requirements 4 1 RSLogix 5000 Preface 2 Spurious failure estimates A 1 T Terminology Used throughout manual Preface 1 W Publication 1794 RM0016 EN P December 2011 2 Index Wiring 1 0 modules Digital input modules 3 3 Analog input modules 3 9 3 15 Digital output modules 3 5 3 6 Analog output modules 3 16 3 17 Publication 1794 RM0016 EN P December 2011 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation c
50. ix 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 This manual is designed to make clear how the FLEX 1 0 with ControlLogix Control System can be SIL2 certified Table Preface 1 lists the information available in each section Section Title Chapter 1 SIL Policy Description Introduction to the SIL policy and how that policy relates to FLEX 1 0 with a ControlLogix system Chapter 2 ControlLogix Communications Description of the ControlLogix communications modules used in the SIL2 certified FLEX 1 0 with ControlLogix system Chapter 3 FLEX 1 0 Modules Description of the FLEX 1 0 modules used in the SIL2 certified FLEX 1 0 with ControlLogix system Chapter 4 General Requirements for Application software requirements for using Application Software 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 Understanding Terminology The following table defines acronyms used in this manual Table Preface 2 List of Acronyms Used Throughout the Safety Application Manual Acronym Full
51. ly accurate level of calibration However because each application is different users are responsible for making sure their FLEX I O modules are 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 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 analog output be calibrated at least every 3 years to verify the accuracy of the input signal and avoid nuisance application shutdowns For typical emergency shutdown ESD applications outputs must be configured to De energize When configuring any FLEX I O output module each output must be configured to de energize in the event of a fault and in the event of the controller going into program mode For exceptions to the typical ESD applications see publication 1756 RMO001 Publication 1794 RM0016 EN P December 2011 3 14 FLEX 1 0 Modules Publication 1794 RM001G EN P December 2011 e Wire Output Back to Input and Examination of Output Data Feedback
52. must determine whether the use of 1 or 2 sensors is appropriate to fulfill SIL2 requirements Two Sensor Wiring Example Input 1 Input 2 SS o 9 HIHI IE MUTH e Input 5555555555555555 Keisisieisisieisisieisisteieisie SH2SENSOR COM 665606600000000000 60000000000000000 24V 6500550030000008 5000000000000000 E I Input 1 Input 2 Input azezas COM IOOOOOOOOOOOOOODOO 24V B8868s6208638d28 0000000000000000 00000000000000000 0000000000000000 Note 1 Both sensors are monitoring the same safety app lica on It 43366A Wiring the Single Ended Input Module in Voltage Mode In addition to following the General Considerations when 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 1 0 Analog Input Module Wiring in Voltage Mode Analog Input 1794 IE8 OOOOOOOOOOOOOO OOOOOOOOOOOOOO VO Transmi age EJ 1794 TB3 ter A 1794 IE8 Analog Input LS E E EEE E E EEE E E EE E E T OOOOOOOOOOOOOO O OQOOOOOOOOOOOOOOO Oo
53. om support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the bestuse of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem 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 United States or Canada 1 440 646 3434 Outside United States or Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact Canada your local Rockwell Automation representative 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 and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United
54. ombo Module 6 317 918 1 58E 07 1 21E 09 1794 IF4IXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 1 04E 09 1794 IFAICFXT 4 Isolated Input Analog Module 7 297 140 1 3 E 07 1 04E 09 1794 0F4IXT 4 Isolated Output Analog Module 5 493 902 1 82E 07 1 42E 09 1794 1J2XT 2 Ch Frequency Counter Module 11 714 128 8 54E 08 6 29E 10 1794 IRT8XT 8 TC RTD Input Analog Module 8 204 792 1 22E 07 9 16E 10 1 MTBF measured in hours Calculated using field based values for components B A Failure Rate 1 MTBF Publication 1794 RM0016 EN P December 2011 A 10 Failure Estimates Notes H Publication 1794 RM001 G EN P December 2011 A Analog input modules 3 7 3 8 Analog output modules 3 13 3 15 Application program Technical SIL2 requirements 5 1 C Calibration 3 7 3 13 Communication ControlNet 2 1 Communications modules 2 1 ControlNet module 2 1 Documentation 2 3 Control and information protocol Definition Preface 1 ControlNet module 2 1 D Diagnostic coverage Definition Preface 1 Documentation Communications modules 2 3 E European norm Definition Preface 1 F Fault reporting Analog input modules 3 7 Analog output modules 3 14 Digital input modules 3 3 Digital output modules 3 4 3 5 G Get system value GSV Defintion Preface 1 l 1 0 modules 3 1 3 19 Analog input modules 3 7 3 8 Analog output modules 3 13 3 15 Calibration 3 7 3 13 Digital input modules 3 2 3 4 Dig
55. one out of one architecture consists of a single channel where any dangerous failure leads to a failure of the safety function 1002 One out of two A 1002 one out of two architecture consists of two channels connected in parallel such that either channel can process the safety function Introduction to SIL Chapter 1 SIL Policy This chapter introduces you to the SIL policy and how the ControlLogix FLEX I O system meets the requirements for SIL2 certification For information about See page Introduction to SIL 1 1 SIL2 Certification 1 2 Proof Tests 1 3 Hardware Designs and Firmware Functions 1 8 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 Certain catalog numbers listed in Table 1 1 on page 1 5 of the FLEX 1 0 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
56. output in series 5 s the control of the external relay implemented in ladder logic r 6 Have you examined the Output Data feedback signal in application logic r r 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 controller own both modules if two of the same type are used in an application 10 Are control diagnostics and alarming functions performed in sequence in application logic 11 s the application logic monitoring one ControlNet status bit for the associated module and is appropriate action invoked via the application logic by these bits No Digital Output Module Only Requirements Yes No Comment 1 For the standard output modules is the Communication Format set to Output Data L 2 For standard output modules have you wired the outputs to a corresponding input to validate that the output is following its commanded state No Analog Output Module 0nly Requirements Yes No Comment 1 Have you calibrated the modules as often as required by your application 2 When wiring the FLEX 1 0 analog output module in current mode are loop devices placed properly 3 Have you written application logic to examine bits for any condition that may cause a fault and appropriate fault routines to handle the fault condition Publication 1794 RM001G EN P December 2011 3 20 FLEX 1 0 Modul
57. put 2 Output Analog Combo Module 11 800 802 8 47E 08 5 99E 10 1794 EBXT 8 Input analog Module 14 041 000 7 12E 08 5 03E 10 1794 OE4XT 4 Output Analog Module 11 381 744 8 79E 08 6 22E 10 1794 IF2XOF2IXT 2 Input 2 Output Isolated Analog Combo Module 6 317 918 1 58E 07 1 13E 09 1794 IFAIXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 9 75E 10 1794 F4ICFXT 4 Isolated Input Analog Module 7 297 140 1 37E 07 9 75E 10 1794 0F4IXT 4 Isolated Output Analog Module 5 493 902 1 82E 07 1 30E 09 1794 1J2XT 2 Ch Frequency Counter Module 11 714 128 8 54E 08 6 04E 10 1794 IRT8XT 8 TC RTD Input Analog Module 8 204 792 1 22E 07 8 66E 10 1 MTBF measured in hours Calculated using field based values for components 3 Failure Rate 1 MTBF Table 1 4 shows an example of a PFD calculation for a safety loop involving two DC input modules used in a 1oo2 configuration and a DC output module Table 1 4 Catalog Number Description MTBF Calculated 1002 PFD 1794 ACNR15 ControlNet Dual Media 3 259 605 1 56E 06 Adapter 1 5 1794 B16 24V DC Input Module 6 409 846 4 34E 06 1794 B16 24V DC Input Module 6 409 846 4 34FE 06 1794 0B16 24V DC Output Module 4 284 857 9 62E 06 1794 OW8 Relay Output Module 1 312 973 1 20E 06 1756 L63B ControlLogix Controller 2 460 065 2 33E 04 1756 CNB ControlNet Bridge Module 3 596 087 1 15E 04 1756 CNB ControlNet Bridge Module 3 596 087 1 15E 04 Total PFD calculation for a
58. scribed 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 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 alae ta Allen Bradley Rockwell Automation FLEX 1 0 RSLinx RSLogix 5000 and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Introduction Manual Set Up Table Preface 1 Preface This application manual is intended to describe the FLEX l 0 with ControlLog
59. signal Users must wire an analog output to an actuator and then back to an analog input to monitor the output s performance The use of feedback transmitters to verify an output s performance is acceptable The application logic must examine the Data Feedback value associated with each output point to make sure that the requested output command from the controller was received by the module The value must be compared to the analog input that is monitoring the output to make sure the value is in an acceptable range for the application In the ladder diagram in Figure 3 12 a user defined percentage of acceptable deviation that is tolerance is applied to the configured range of the analog 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 accommodate an acceptable fault response time and any communication filtering or output lags in the system If the monitoring input value and the Output Feedback miscompare for longer than the preset value a fault is registered with a corresponding alarm Figure 3 12 Monitoring an Analog Output with an Analog Input
60. ts 3 18 Checklist for SIL Outputs 3 19 In the most basic description there are two types of SIL2 certified FLEX 1 0 modules Digital I O modules Analog I O modules With each type however there are differences between specific modules Because the differences propagate to varying levels in each module type a graphical representation can best provide an overview of the many SIL2 certified FLEX I O modules 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 Publication 1794 RM0016 EN P December 2011 3 2 FLEX 1 0 Modules Using Digital Input Modules Publication 1794 RM001G EN P December 2011 General Considerations when using Any FLEX 1 0 Digital Input Module Regardless of the type of FLEX I O input module used there are a number of general application considerations that users must follow when applying these modules in a SIL2 application Proof Tests Periodically for example once every several years 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
61. used in a 1002 configuration for SIL 2 e Adapters must be used in a 1002 e Outputs may be 1002 in series or 1001 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 1001 PFDs must be used for each e The total PFD for two 1001s is the sum of both Mattia 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 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
62. ut Module 4 105 090 2 44E 07 4 34E 06 1794 IE8 Analog Input Module 37 952 679 2 63E 08 4 64E 07 1794 IF2X0F2I Isolated Analog Input Output Module 25 296 960 3 95E 08 6 97E 07 1794 IFAI Isolated Analog Input Module 11 746 343 8 51E 08 1 50E 06 1794 1J2 Frequency Counter Module 2 418 321 4 14E 07 7 45E 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 0B16 16 Source Output Module 1 883 594 5 31E 07 9 62E 06 1794 0B16P Protected Output Module 2 135 280 4 68E 07 8 46E 06 1794 OB8EP Protected Output Module 2 389 669 4 18E 07 7 54E 06 1794 0E4 Analog Output Module 23 807 086 4 20E 08 7 41E 07 1794 0F4I Isolated Analog Output Module 7 191 128 1 39E 07 2 47E 06 1794 OW8 Relay Output Module 14 766 876 6 77E 08 1 20E 06 1794 TB3 Terminal Base Units 21 128 346 4 73E 08 8 35E 07 1794 TB3G Generic Terminal Base Units 27 320 800 3 66E 08 6 45E 07 1794 TB3GS Generic Terminal Base Units 46 425 600 2 15E 08 3 79E 07 1794 TB3S Terminal Base Unit 71 433 747 1 40E 08 2 46E 07 1794 TB3T Temperature Terminal Base Units 73 096 226 1 37E 08 2 41E 07 1794 TB3TS Temperature Terminal Base Units 75 763 3990 1 32E 08 2 32E 07 1794 TBN Terminal Base Units 75 716 615 1 32E 08 2 32E 07 1794 TBNF Fused Terminal Base Units 4 812 320 2 08E 07 3 70E 06 1794 ACNR15XT ControlNet Redundant Me

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