Spec Sheet - The Reynolds Company

Spec Sheet - The Reynolds Company
Safety Reference Manual
Using ControlLogix in SIL 2 Applications
Catalog Numbers 1756-L6x, 1756-L7x
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
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.
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.
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.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Allen-Bradley, ControlLogix, ControlLogix-XT, ControlNet, Data Highway Plus, DeviceNet, EtherNet/IP, FactoryTalk, FLEX, FLEX I/O-XT, GuardLogix, Logix 5000, Rockwell Software, RSNetWorx and SynchLink are
trademarks of Rockwell Automation, Inc.
ControlNet, DeviceNet and EtherNet are trademarks of the ODVA.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Summary of Changes
This manual contains new and updated information. Changes throughout this
revision are marked by change bars as shown to the right of this paragraph.
New and Updated
Information
This table lists the major changes made with this revision.
Change
Page
Updated table listing communication modules in the Introduction to Communication Modules section 43
Updated Table - 1-Year PFD Calculations
119
Updated Table - 2-Year PFD Calculations
124
Updated Table - 5-year PFD Calculations
129
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Summary of Changes
Notes:
4
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Table of Contents
Preface
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 1
SIL Policy
Introduction to Safety Integrity Level (SIL) . . . . . . . . . . . . . . . . . . . . . . . .
Programming and Debugging Tool (PADT). . . . . . . . . . . . . . . . . . . .
About the ControlLogix System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas and Fire Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler and Combustion Considerations . . . . . . . . . . . . . . . . . . . . . . . .
Typical SIL 2 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Simplex Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duplex Logic Solver Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duplex System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proof Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proof Testing with Redundancy Systems . . . . . . . . . . . . . . . . . . . . . . .
Reaction Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reaction Times in Redundancy Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Certifications and Compliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
14
14
16
17
17
24
25
28
29
30
30
31
31
Chapter 2
Features of the ControlLogix
SIL 2 System
Module Fault Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Echo Communication Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ControlNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EtherNet/IP Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Keying of Modules in SIL 2 Applications. . . . . . . . . . . . . . . . .
33
34
35
35
36
36
36
37
37
Chapter 3
ControlLogix Controllers, Chassis,
and Power Supplies
ControlLogix Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements for Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ControlLogix Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ControlLogix Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommendations for Using Power Supplies . . . . . . . . . . . . . . . . . . .
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Table of Contents
Chapter 4
ControlLogix Communication
Modules
Introduction to Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . .
ControlNet Modules and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ControlNet Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ControlNet Repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ControlNet Module Diagnostic Coverage . . . . . . . . . . . . . . . . . . . . . .
EtherNet/IP Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DeviceNet Scanner Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Highway Plus - Remote I/O Module (1756-DHRIO) . . . . . . . . . .
SynchLink Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Requirements for Communication Networks . . . . . . . . . . . . . . .
Peer-to-Peer Communication Requirements. . . . . . . . . . . . . . . . . . . . . . . .
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
44
44
44
44
45
45
45
45
46
46
47
Chapter 5
ControlLogix I/O Modules
6
Overview of ControlLogix I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using 1756 Digital Input Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements When Using Any ControlLogix
Digital Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring ControlLogix Digital Input Modules. . . . . . . . . . . . . . . . . . . .
Using 1756 Digital Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements When Using ControlLogix
Digital Output Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring ControlLogix Digital Output Modules. . . . . . . . . . . . . . . . . .
Using 1756 Analog Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduct Proof Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibrate Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use the Floating Point Data Format. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program to Respond to Faults Appropriately. . . . . . . . . . . . . . . . . . . .
Program to Compare Analog Input Data . . . . . . . . . . . . . . . . . . . . . . .
Configure Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specify the Same Controller as the Owner . . . . . . . . . . . . . . . . . . . . . .
Wiring ControlLogix Analog Input Modules . . . . . . . . . . . . . . . . . . .
Using 1756 HART Analog Input Modules . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring the HART Analog Input Modules . . . . . . . . . . . . . . . . . . . . . .
Using 1756 Analog Output Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Considerations for Using Analog Output Modules . . . . . . . . . . . . . .
Wiring ControlLogix Analog Output Modules . . . . . . . . . . . . . . . . .
Using 1756 HART Analog Output Modules . . . . . . . . . . . . . . . . . . . . . . .
Wiring the HART Analog Output Modules . . . . . . . . . . . . . . . . . . . .
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58
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60
60
60
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65
66
67
69
71
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Table of Contents
Chapter 6
FLEX I/O Modules
Overview of FLEX I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using 1794 Digital Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements When Using FLEX I/O Digital
Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring FLEX I/O Digital Input Modules . . . . . . . . . . . . . . . . . . . . . .
Using 1794 Digital Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements When Using FLEX I/O Digital Output Modules .
Wiring FLEX I/O Digital Output Modules . . . . . . . . . . . . . . . . . . . .
Using 1794 Analog Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements When Using FLEX I/O Analog Input Modules . . .
Wiring FLEX I/O Analog Input Modules . . . . . . . . . . . . . . . . . . . . . .
Using 1794 Analog Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements When Using FLEX I/O Analog Output Modules .
Wiring FLEX I/O Analog Output Modules . . . . . . . . . . . . . . . . . . . .
73
73
73
74
75
75
76
77
77
80
84
84
87
Chapter 7
Requirements for Application
Development
Software for SIL 2-Related Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIL 2 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basics of Application Program Development and Testing. . . . . . . . . . . .
Functional Specification Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensors (digital or analog) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Creating the Application Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logic and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Language. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIL Task/Program Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forcing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Application Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Verify Download and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning Life Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Your Application Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
89
90
90
90
91
92
93
93
93
93
93
94
94
94
94
95
96
97
Chapter 8
Faults in the ControlLogix System
Detecting and Reacting to Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Module Fault Reporting for Any ControlLogix or
FLEX I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Checking Keyswitch Position with GSV Instruction . . . . . . . . . . . . . . . 100
Examining an 1756 Analog Input Module’s High Alarm . . . . . . . . . . . 101
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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Table of Contents
Chapter 9
Use of Human-to-Machine Interfaces Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Accessing Safety-related Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Reading Parameters in Safety-related Systems . . . . . . . . . . . . . . . . . . 103
Changing Safety-related Parameters in SIL-rated Systems . . . . . . . 104
Appendix A
Reaction Times of the
ControlLogix System
Local Chassis Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Chassis Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculating Worst-case Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For Digital Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For Analog Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
108
108
108
110
Appendix B
SIL 2-certified ControlLogix
System Components
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Appendix C
PFD and PFH Calculations
for a SIL 2 System
About PFD and PFH Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determine Which Values To Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About the Calculations in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-Year PFD Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-Year PFD Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-year PFD Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Component Values To Calculate System PFD . . . . . . . . . . . . . . .
Example: 1-year PFD Calculation for a ControlLogix
System (1oo1 Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: 1-year PFD Calculation for a ControlLogix
System (1oo2 Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117
118
118
119
124
129
134
134
134
Appendix D
Using ControlLogix and FLEX I/O
Modules in SIL 1 Applications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Appendix E
Checklists
Checklist for the ControlLogix System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist for SIL Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist for SIL Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist for the Creation of an Application Program . . . . . . . . . . . . . .
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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Preface
This safety reference manual is intended to do the following:
• Describe the ControlLogix® Control System components available from
Rockwell Automation that are suitable for use in low demand and high
demand (no more than 10 demands per year) safety-related control, up to
and including SIL 2 applications
• Provide safety-related information specific to the use of ControlLogix
modules in SIL 2 systems - including PFD calculations that need to be
considered for SIL 2-certified systems
• Explain some possible SIL 2-certified system configurations
• Describe basic programming techniques for the implementation of
ControlLogix SIL 2-certified systems with references and links to moredetailed programming and implementation techniques
IMPORTANT
Terminology
This manual describes typical SIL 2 implementations using ControlLogix
equipment. Keep in mind that the descriptions presented in this manual do
not preclude other methods of implementing a SIL 2-compliant system by
using ControlLogix equipment.
Other methods should be reviewed and approved by a recognized certifying
body, such as TÜV Rheinland Group.
This table defines abbreviations used in this manual.
Table 1 - Abbreviations Used throughout This Reference Manual
Abbreviation
Full Term
Definition
CIP
Common Industrial
Protocol
A industrial communication protocol used by Logix5000™-based automation
systems on EtherNet, ControlNet, and DeviceNet communication networks.
CL
Claim Limit
The maximum level that can be achieved.
DC
Diagnostic Coverage
The ratio of the detected failure rate to the total failure rate.
—
Demand
A safe-state safety action initiated by the safety function.
A normal control action/function is not a safety demand. A safety demand
occurs when safety conditions are met. Typically this only occurs when
standard control fails to perform its control function
—
Demand Rate
The expected rate (per year) that a safe-state safety action will be executed
by the safety function.
EN
European Norm.
The official European Standard.
GSV
Get System Value
A ladder logic instruction that retrieves specified controller information and
places it in a destination tag.
MTBF
Mean Time Between
Failures
Average time between failure occurrences.
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Preface
Table 1 - Abbreviations Used throughout This Reference Manual
10
Abbreviation
Full Term
Definition
MTTR
Mean Time to
Restoration
Average time needed to restore normal operation after a failure has occurred.
PADT
Programming and
Debugging Tool
RSLogix™ 5000 software is used to program and debug a SIL 2-certified
ControlLogix application.
PC
Personal Computer
Computer used to interface with, and control, a ControlLogix system via the
RSLogix 5000 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.
SFF
Safe Failure Fraction
The ratio of safe failure plus dangerous detected failure to total failures.
SIL
Safety Integrity Level A discrete level for specifying the safety integrity requirements of the safety
functions allocated to the electrical/electronic/ programmable electronic (E/
E/PE) part of the safety system.
STR
Spurious Trip Rate
That part of the overall failure rate that does not lead to a dangerous
undetected failure.
TCE
Channel Equivalent
Mean Downtime
The sum of downtime contributions from both the dangerous detected
failure rate and the dangerous undetected failure rate, on a per channel basis
TGE
System Equivalent
Downtime
The sum of downtimes resulting from dangerous detected and dangerous
undetected failure rates associated with both channels.
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Preface
Additional Resources
These resources contain more information related to the ControlLogix system.
Resource
Description
ControlLogix SIL 2 System Configuration Using RSLogix
5000 Subroutines, publication 1756-AT010
Explains how to configure a SIL 2-certified system by using
subroutines provided by Rockwell Automation.
ControlLogix SIL 2 System Configuration Using RSLogix
5000 Subroutines, publication 1756-AT012
Explains how to configure a SIL 2-certified system by using
Add-On Instructions provided by Rockwell Automation.
Logix5000 Controllers General Instruction Set Reference
Manual, publication 1756-RM003
Contains descriptions and use considerations of general
instructions available for Logix5000 controllers.
ControlLogix System User Manual, publication 1756UM001
Explains how to use the ControlLogix controllers.
ControlLogix Standard Redundancy System User Manual,
publication 1756-UM523
Explains how to install, configure, and use a standard
redundancy system.
ControlLogix Enhanced Redundancy System User Manual,
publication 1756-UM535
Explains how to install, configure, and use an enhanced
redundancy system.
ControlLogix Digital I/O User Manual, publication 1756UM058
Provides information about the use of ControlLogix digital
I/O modules.
ControlLogix Analog I/O Modules User Manual, publication Provides information about the use of ControlLogix analog
1756-UM009
I/O modules.
Logix5000 Controllers Execution Time and Memory Use
Reference, publication 1756-RM087
Provides estimated execution times that can be used in
worst-case scenario calculations.
Logix5000 Controllers Common Procedures Programming
Manual, publication 1756-PM001
Explains a variety of programming-related topics.
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Provides general guidelines for installing a Rockwell
Automation industrial system.
Product Certifications website, http://www.ab.com
Provides declarations of conformity, certificates, and other
certification details.
In addition to the manuals listed, you may want to reference installation
instructions listed in Appendix B.
You can view or download publications at http://
www.rockwellautomation.com/literature/. To order paper copies of technical
documentation, contact your local Allen-Bradley® distributor or Rockwell
Automation sales representative.
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
11
Preface
Notes:
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Chapter
1
SIL Policy
Introduction to Safety
Integrity Level (SIL)
Topic
Page
Introduction to Safety Integrity Level (SIL)
13
Typical SIL 2 Configurations
17
Typical SIL 2 Configurations
17
Proof Tests
28
Reaction Times
30
Reaction Times in Redundancy Systems
30
Safety Watchdog
31
Safety Certifications and Compliances
31
Certain catalog numbers of the ControlLogix system (listed in Appendix B) are
type-approved and certified for use in SIL 2 applications according to these
standards:
• IEC 61508, edition 2, 2010 (this manual describes architectures required
to achieve edition 2)
• IEC 61511
Approval 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
SIL 2 criteria. The results make the ControlLogix system suitable up to and
including SIL 2 for demand rates up to and including ten demands per year.
The TÜV Rheinland Group has approved the ControlLogix system for use in up
to, and including, SIL 2 safety-related applications in which the de-energized
state is typically 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.
Life expectancy for the ControlLogix system components is 20 years.
IMPORTANT
Keep in mind that a demand is an event where the safety function is executed.
A ControlLogix system can be configured to execute standard control as well as
safety functions. The demand rate is determined by how often the safety
function is executed and not how often the control function is executed.
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Programming and Debugging Tool (PADT)
For support in creation of programs, the PADT (Programming and Debugging
Tool) is required. The PADT for ControlLogix is RSLogix™ 5000 software, per
IEC 61131-3, and this Safety Reference Manual.
For more information about programming a system by using optional predeveloped Add-On Instructions, refer to ControlLogix SIL 2 System
Configuration Using SIL 2 Add-On Instructions, publication 1756-AT012.
About the ControlLogix System
The ControlLogix system is a modular programmable automation system with
the ability to pre-configure outputs and other responses to fault conditions. As
such, a system can be designed to meet requirements for ‘hold last state’ in the
event of a fault so that the system can be used in up to, and including, SIL 2-level
Gas and Fire and other applications that require that output signals to actuators
remain ON. By understanding the behavior of the ControlLogix system for an
emergency shutdown application, you can incorporate appropriate system design
measures to meet other application requirements. These measures relate to the
control of outputs and actuators, which must remain ON to be in a safe state.
Other requirements for SIL 2 (inputs from sensors, software used, and so on)
must also be met.
IMPORTANT
When used in accordance with the information in this manual and the relevant
safety standards, the ControlLogix system is suitable for applications up to and
including SIL 2, where the demand rate is no more than 10 times per year.
Gas and Fire Considerations
Listed below are the measures and modifications related to the use of the
ControlLogix system in Gas and Fire applications.
• The use of a manual override is necessary to make sure the operator can
maintain the desired control in the event of a controller failure. This is
similar in concept to the function of the external relay or redundant
outputs required to make sure a de-energized state is achieved for an ESD
system should a failure occur (for example, a shorted output driver) that
would prevent this from normally occurring. The system knows it has a
failure, but the failure state requires an independent means to maintain
control and either remove power or provide an alternate path to maintain
power to the end actuator.
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Chapter 1
• If the application cannot tolerate an output that can fail shorted
(energized), then an external means such as a relay or other output must be
wired in series to remove power when the fail shorted condition occurs.
See Wiring ControlLogix Digital Output Modules on page 54 for more
information.
• If the application cannot tolerate an output that fails open (de-energized),
then an external means such as a manual override or output must be wired
in parallel. See Figure 1. The user must supply the alternative means and
develop the application program to initiate the alternate means of
removing or continuing to supply power in the event the main output fails.
• This manual override circuit is shown in Figure 1. It is composed of a
hard-wired set of contacts from a selector switch or push-button. One
normally-open contact provides for the bypass of power from the
controller output directly to the actuator. The other is a normally-closed
contact to remove or isolate the controller output.
• An application program needs to be generated to monitor the diagnostic
output modules for dangerous failures such as shorted or open-output
driver channels. Diagnostic output modules must be configured to hold
last state in the event of a fault.
• A diagnostic alarm must be generated to inform the operator that manual
control is required.
• The faulted module must be replaced within the Mean Time to
Restoration (MTTR).
• Any time a fault is detected, the system must annunciate the fault to an
operator by some means (for example, an alarm light).
Figure 1 - Manual Override Circuit
L1
Manual Override
Actuator
L2 or Ground
43379
Fault
Alarm to Operator
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SIL Policy
Boiler and Combustion Considerations
If your SIL 2-certified ControlLogix system is used in combustion-related
applications, you are responsible for meeting appropriate safety standards
including National Fire Protection Association (NFPA) standard NFPA 85 and
86. In addition, you must provide a documented life-cycle system safety analysis
that addresses all the requirements of NFPA 85 related to Burner Management
System Logic.
To comply with the requirements of IEC 61508, the safety demand rate must be
no more than 10 demands per year.
You should also consider system reaction capability as explained in Appendix A.
If your system must meet standard EN 50156, then you must also meet the
requirements identified in the current version of EN 50156. To use FLEX™ I/O
or 1756-series I/O modules in SIL 2 EN50156 applications, you must use a
GuardLogix® controller. Refer to the GuardLogix Safety Reference Manual,
publication 1756-RM093.
IMPORTANT
16
When using a GuardLogix controller with SIL 2-rated 1756 or 1794 I/O, you
must also follow the requirements defined in this manual.
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Typical SIL 2 Configurations
Chapter 1
SIL 2-certified ControlLogix systems can be used in standard (simplex) or highavailability (duplex) configurations. For the purposes of documentation, the
various levels of availability that can be achieved by using various ControlLogix
system configurations are referred to as simplex or duplex.
This table lists each system configuration and the hardware that is part of the
system’s safety loop.
System Configuration
Safety Loop Includes
Simplex Configuration on page 17
• Single controller
• Single communication module
• Dual I/O modules
Duplex Logic Solver Configurations on page 24
• Dual controllers
• Dual communication modules
• Dual I/O modules
Duplex System Configuration on page 25
•
•
•
•
IMPORTANT
Dual controllers
Dual communication modules
Dual I/O modules
I/O termination boards
The system user is responsible for the following tasks when any of the
ControlLogix SIL 2 system configurations are used:
• The setup, SIL rating, and validation of any sensors or actuators
connected to the ControlLogix control system
• Project management and functional testing
• Programming the application software and the module configuration
according to the descriptions in this manual
The SIL 2 portion of the certified system excludes the development tools
and display/human machine interface (HMI) devices; these tools and
devices must not be part of the safety loop.
Simplex Configuration
In a simplex configuration, the hardware used in the safety loop is programmed to
fail to safe. The failure to safe is typically an emergency shutdown (ESD) where
outputs are de-energized.
Figures 2 …9 each show typical simplex SIL loops. The figures show the
following:
• Overall safety loop
• ControlLogix portion of the overall safety loop
SIL 2 I/O modules in the safety loop must meet the requirements specified in
Chapter 5, ControlLogix I/O Modules and Chapter 6, FLEX I/O Modules.
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SIL Policy
Figure 2 - Single-chassis Configuration
Overall Safety Loop
SIL 2-certified ControlLogix Safety Loop
Output A
Actuator
Output B
Input A
Input B
Sensor
1756-EN2T
1756-EN2TR
Controller Chassis
Standard Communication
Figure 3 - Fail-safe ControlLogix EtherNet/IP DLR Configuration
Overall Safety Loop
SIL 2-certified ControlLogix Safety Loop
Standard
Communication
1756-EN2TR
Input 3B
Output 4B
Remote I/O Chassis
EtherNet/IP
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
EtherNet/IP
1756-EN2TR
Input 3A
Output 4A
Remote I/O Chassis
EtherNet/IP
18
Output2B
Output2A
Input1B
1756-EN2TR
1756-EN2T
1756-EN2TR
Sensor
Input 1A
Remote I/O Chassis
Controller Chassis
Actuator
SIL Policy
Chapter 1
Figure 4 - Fail-safe ControlLogix ControlNet Configuration
(Safety and Standard Connections on the Same Network)
Overall Safety Loop
SIL 2-certified ControlLogix Safety Loop
1756-CN2R
Input Ch A
Output Ch A
1756-CN2R
Remote I/O Chassis
1756-CN2
Controller Chassis
ControlNet
Standard
Communication
1756-CN2
Input Ch B
Output Ch B
Remote I/O Chassis
Dual networks are required because
one of the ControlNet networks
includes standard devices, that is, those
that are not SIL 2-rated.
In Figure 5, non-SIL 2 communication on separate subnets lets you place
redundant channel I/O in the same rack.
Figure 5 - Fail-safe ControlLogix ControlNet Configuration with Non-SIL 2 Communication
(Safety and Standard Connections on Separate Networks)
Overall Safety Loop
SIL 2-certified ControlLogix Safety Loop
Output 2B
Input 1B
Input 1A
1756-CN2
1756-CN2
1756-EN2T
Standard
Communication
Output 2A
Remote I/O Chassis
Controller Chassis
ControlNet
1756-CN2
ControlNet
1756-CN2
Output4B
Remote I/O Chassis
Input 3B
Dual networks are not required because
a separate network is being used for
standard devices.
Output 4A
Input 3A
Remote I/O Chassis
ControlNet
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SIL Policy
Figure 6 - Fail-safe ControlLogix EtherNet/IP Configuration: Single DLR Loop for Safety and
Standard Communication
Overall Safety Loop
SIL 2-certified ControlLogix Safety Loop
1756-EN2TR
1756-EN2TR
Controller Chassis
Standard
Communication
DLR
Remote I/O Chassis
1756-EN2TR
Output A
Input A
EtherNet/IP
EtherNet/IP
Standard
Communication
DLR
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1756-EN2TR
Output B
Input B
Remote I/O Chassis
SIL Policy
Chapter 1
Figure 7 - Fail-safe ControlLogix EtherNet/IP Configuration with FLEX I/O Modules: Single DLR
Loop for Safety and Standard Communication
Overall Safety Loop
SIL 2-certified ControlLogix Safety Loop
1756-EN2TR
1756-EN2TR
Controller Chassis
Standard
Communication
DLR
EtherNet/IP
1794-AENTR
DI1
DO1
1794-AENTR
DI1
DO1
EtherNet/IP
Standard
Communication
DLR
IMPORTANT
As shown in Figure 6 and Figure 7, standard devices can reside within an
EtherNet/IP™ SIL 2 subnet provided the following requirements are met:
• The EtherNet/IP subnet topology must be DLR.
• The ControlLogix chassis must have two 1756-EN2TR modules.
– Independent connection paths must be established for channels A and
B I/O through each ControlLogix chassis bridge module.
• Channel A and Channel B I/O must reside in separate chassis or connected
to separate adapters.
• Direct Internet connectivity must be limited to EtherNet/IP bridge modules
listed in Appendix B of this manual.
Direct Internet connections via other standard devices are not allowed.
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SIL Policy
Figure 8 - Fail-safe ControlLogix Configuration with FLEX I/O Modules on ControlNet Network
HMI
For Diagnostics and Visualization
(see special instructions in Chapter 9 for
writing to safety-related controllers in the
safety loop)
Programming Software
For SIL applications, a programming
terminal is not normally connected.
Plant-wide Ethernet/Serial
Overall Safety Loop
SIL 2-certified ControlLogix components’ portion of the overall safety loop.
DI1
1756-CN2R
1756-ENBT
1794 FLEX I/O – Rail A
DO1
Actuator
Actuator
ControlNet
To other safety-related
ControlLogix or FLEX I/O remote I/
O chassis
1794 FLEX I/O – Rail B
DI2
Input Device
DO2
Input Device
ControlNet
+V
To other safety-related ControlLogix or FLEX I/O remote I/O chassis.
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 SIL 2 approved.
Note 2: Two adapters are required for meeting SIL 2 as shown in the figure. The adapters can be either ControlNet or Ethernet and must be from the list of approved products.
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Chapter 1
Figure 9 - Fail-safe ControlLogix Configuration with FLEX I/O Modules on EtherNet/IP Network
HMI
For Diagnostics and Visualization
(see special instructions in Chapter 9 for
writing to safety-related controllers in the
safety loop)
Programming Software
For SIL applications, a programming
terminal is not normally connected.
Plant-wide Ethernet/Serial
Overall Safety Loop
SIL 2-certified ControlLogix components’ portion of the overall safety loop.
1794AENTR
1756-EN2TR
1756-ENBT
1794 FLEX I/O
DI1
DO1
Actuator
Actuator
EtherNet/IP
Input Device
1794AENTR
DI2
DO2
Input Device
EtherNet/IP
+V
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SIL Policy
Duplex Logic Solver Configurations
In duplex configurations, redundant system components are used to increase the
availability of the control system. The modules in the redundant controller
chassis include redundancy modules and network communication modules for
redundant communication, as well as the ControlLogix controllers.
SIL 2 I/O modules in the safety loop must meet the requirements specified in
Chapter 5, ControlLogix I/O Modules.
Figure 10 - Typical SIL Loop with Controller Chassis Redundancy
HMI
For Diagnostics and Visualization (see special instructions in Chapter 9 for
writing to safety-related controllers in the safety loop)
Programming Software
For SIL applications, a programming
terminal is not normally connected.
Plant-wide Ethernet/Serial
Overall Safety
Loop
SIL 2-certified ControlLogix components’ portion of the overall safety loop.
1756-CN2
1756-RM
1756-CN2
1756-CN2
1756-EN2T
I/O
I/O
1756-CN2
Remote I/O Chassis Ch B
Remote I/O Chassis Ch A
Primary Chassis
ControlNet
IMPORTANT: You can also access a remote I/O chassis via an
EtherNet/IP network if you use ControlLogix Enhanced
Redundancy System, Revision 20.54 or later.
To nonsafety-related systems outside the ControlLogix
portion of the SIL 2-certified loop.
ControlNet
IMPORTANT
24
To other safetyrelated
ControlLogix
and remote I/O
chassis.
1756-RM
1756-CN2
1756-CN2
1756-EN2T
Secondary Chassis
The redundant (duplex) ControlLogix system in Figure 10 provides logic
solver fault tolerance.
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SIL Policy
Chapter 1
Figure 10 shows a typical duplex SIL loop. The figure also shows the following:
• Overall safety loop
• ControlLogix portion of the overall safety loop
• How other devices (for example, HMI) connect to the loop, while
operating outside the loop
Duplex System Configuration
This configuration of the ControlLogix system uses fully-redundant controllers,
communication modules, and remote I/O devices to achieve enhanced
availability.
Figure 11 - Duplex System EtherNet/IP Configuration
Overall Safety Loop
1756-EN2TR
1756-EN2TR
EtherNet/IP
non-SIL 2 EtherNet/IP connections
Digital Input
Termination Board
Field Device
non-SIL 2 EtherNet/IP connections
Input Ch B
Output Ch B
Output Ch B
1756-EN2TR
I/O Chassis B
Input Ch A
Output Ch A
Input Ch A
1756-EN2TR
I/O Chassis A
Analog Input
Termination Board
SIL 2-certified ControlLogix Safety Loop
Secondary Chassis
1756-EN2TR
1756-EN2TR
ControlLogix Chassis
Digital Output
Termination Board
Field Device
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Field Device
25
Chapter 1
SIL Policy
Figure 12 - Duplex System EtherNet/IP Fiber Configuration
1783-ETAP1F
1756-EN2TR
1756-EN2TR
Secondary Chassis
1756-EN2TR
1756-EN2TR
ControlLogix Chassis
1783-ETAP1F
Fiber
Fiber
1783-ETAP1F
1783-ETAP2F
1756-EN2TR
Input Ch B
Output Ch B
I/O Chassis B2
Input Ch A
Output Ch A
1756-EN2TR
I/O Chassis A2
1783-ETAP
Input Ch B
Output Ch B
1783-ETAP1F
1783-ETAP2F
1783-ETAP
I/O Chassis B1
1756-EN2TR
1756-EN2TR
Input Ch A
Output Ch A
I/O Chassis A1
1783-ETAP
Note: All SIL 2 guidelines for 1756 or FLEX I/O modules remain the same.
Because channel A and channel B are two independent networks, 1783-ETAP
modules can be considered black channel equipment and do not need to be part
of the SIL 2 system calculation.
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Chapter 1
1756-EN2TR
1756-EN2TR
1756-RM
1756-EN2TR
1756-RM
1756-EN2TR
Figure 13 - Duplex System with Stratix Switches
ControlLogix
Chassis
ControlLogix
Chassis
Fiber
Copper
Input Ch B
Output Ch B
1756-EN2TR
Output ChB
1756-EN2TR
1756-EN2TR
Output Ch A
Input Ch A
Input Ch B
Chassis 1B
Chassis 1A
Chassis 2B
1756-EN2TR
Input Ch A
Output Ch A
Chassis 2A
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SIL Policy
Figure 14 - Duplex System ControlNet Configuration
Overall Safety Loop
ControlLogix Chassis
Secondary Chassis
SIL 2-certified ControlLogix Safety Loop
ControlNet
I/O Chassis B
Analog Input
Termination Board
Input Ch B
Output Ch B
Input Ch A
Output Ch A
I/O Chassis A
Digital Input
Termination Board
Field Device
Digital Output
Termination Board
Field Device
Field Device
The duplex system configuration uses safety and programming principles
described in this manual, as well as programming and hardware described in the
application technique manuals.
For more information about the ControlLogix SIL 2-certified system, refer to
ControlLogix SIL 2 System Configuration Using SIL 2 Add-On Instructions,
publication 1756-AT012.
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 time frame is
appropriate based on the SIL verification calculation) and could include some of
the following tests:
• Test all safety application fault routines to verify that process parameters
are monitored properly and the system reacts properly when a fault
condition arises.
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Chapter 1
• Test all digital input or output channels to verify that they are not stuck in
the ON or OFF state.
– Manually cycle inputs to make sure that all inputs are operational and
not stuck in the ON state.
– Manually test outputs that do not support runtime pulse testing. The
relays in the redundant power supplies must be tested to make sure
they are not stuck in the closed state.
Users can automatically perform proof tests by switching ground open
on input modules and checking to make sure all input points go to zero
(turn OFF.).
• Calibrate analog input and output modules to verify that accurate data is
obtained from and used on the modules.
IMPORTANT
Each specific application has its own time frame for the proof test interval.
Proof Testing with Redundancy Systems
A ControlLogix redundancy system uses an identical pair of ControlLogix
chassis to keep your process running if a problem occurs with one of those chassis.
When a failure occurs in the primary chassis, control switches to the
secondary controller.
The switchover can be monitored so that the system notifies the user when it has
occurred. In this case (that is, when a switchover takes place), we recommend that
you replace the failed controller within the mean time to restoration (MTTR)
for your application.
If you are using controller redundancy in a SIL 2 application, you must perform
the proof test on the primary controller and on the secondary controller.
TIP
If you are concerned about the availability of the secondary controller if the
primary controller fails, it is good engineering practice to implement a
switchover periodically (for example, once per proof test interval).
For more information on switchovers in ControlLogix redundancy systems and
ControlLogix redundancy systems in general, see these redundancy system
manuals:
• ControlLogix Standard Redundancy System User Manual, publication
1756-UM523
• ControlLogix Enhanced Redundancy System User Manual, publication
1756-UM535
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Reaction Times
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 controller’s
logic program, and then to initiate the appropriate output signal to an actuator.
The system response time is the sum of the following:
• Input hardware delays
• Input filtering
• I/O and communication module RPI settings
• Controller program scan times
• Output module propagation delays
• Redundancy system switchover times (applicable in duplex systems)
Each of the times listed is variably dependent on factors such as the type of I/O
module and instructions used in the logic program. For examples of how to
perform these calculations, see Appendix A, Reaction Times of the ControlLogix
System.
For more information on the available instructions and for a full description of
logic operation and execution, see the following publications:
• Logix5000™ Controllers General Instruction Set Reference Manual,
publication 1756-RM003
• ControlLogix System User Manual, publication 1756-UM001
Reaction Times in
Redundancy Systems
The worst-case reaction time of a duplex system is different than a simplex
system. The redundancy system has a longer reaction time because of the
following:
• There are a series of cross-loading operations that continuously occur
between the primary and secondary controllers. Cross-loading fresh data
at the end of each program scan increases scan time.
To minimize scan time by reducing cross-loading overhead, you can plan
your project more efficiently (for example, minimize the use of SINT,
INT, and single tags, and use arrays and user-defined data structures).
Generally, the primary controller in a duplex system has a 20% slower
response time than the controller in a simplex system.
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• The switchover between controllers slows system response. The
switchover time of a redundancy system depends on the network update
time (NUT) of the ControlNet™ network.
For more information about switchover times in redundancy systems, see
one of these ControlLogix redundancy system user manuals:
– ControlLogix Standard Redundancy System User Manual,
publication 1756-UM523
– ControlLogix Enhanced Redundancy System User Manual,
publication 1756-UM535
IMPORTANT
Safety Watchdog
To avoid nuisance trips, you must account for the additional cross checking
time of a duplex system when setting the watchdog time.
Configure the properties of the task used for safety correctly for your application.
• Priority: must be the highest-priority task in the application (lowest
number)
• Watchdog: the value entered for the SIL 2 safety task must be large enough
for all logic in the task to be scanned
If the task execution time exceeds the watchdog time, a major fault occurs on the
controller. Users must monitor the watchdog and program the system outputs to
transition to the safe state (typically the OFF state) in the event of a major fault
occurring on the controller. For more information on faults, see
Chapter 8, Faults in the ControlLogix System.
See the ControlLogix System User Manual, publication 1756-UM001, for more
information about setting the watchdog.
Safety Certifications and
Compliances
Diagnostic hardware and firmware functions, as well as how you apply
ControlLogix components, enable the system to achieve CL SIL 2 compliance.
IMPORTANT
You must implement these requirements or at minimum the intent of the
requirements defined in this manual to achieve CL SIL 2.
ControlLogix products referenced in this manual may have safety certifications
in addition to the SIL certification. If a product has achieved agency certification,
it is marked on the product label. To view additional safety certifications for
products, go to http://www.ab.com and click the Product Certifications link.
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Notes:
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Chapter
2
Features of the ControlLogix SIL 2 System
Topic
Page
Module Fault Reporting
33
Data Echo Communication Check
34
Pulse Test
35
Software
35
Communication
36
Electronic Keying of Modules in SIL 2 Applications
37
The diagnostic methods and techniques used in the ControlLogix platform let
you configure and program ControlLogix controllers to perform checks on the
total system, including configuration, wiring, and performance, as well as
monitoring input sensors and output devices. Timestamping of I/O and
diagnostic data also aid in diagnostics.
If an anomaly (other than automatic shutdown) is detected, the system can be
programmed to initiate user-defined fault handling routines. Output modules
can turn OFF selected outputs in the event of a failure. Diagnostic I/O modules
self-test to make sure that field wiring is functioning. Output modules use pulse
testing to make sure output switching devices are not shorted.
Module Fault Reporting
Every module in the system is ‘owned’ by one controller. Multiple controllers can
share data, in addition to consuming data from non-owned modules. When a
controller ‘owns’ an I/O module, that controller stores the module’s
configuration data, defined by the user; this data dictates how the module
behaves in the system. Inherent in this configuration and ownership is the
establishment of a ‘heartbeat’ between the controller and module, known as the
requested packet interval (RPI).
The RPI defines a time interval in which the controller and I/O module must
communicate with each other. If, for any reason, communication cannot be
established or maintained (that is, the I/O module has failed, the communication
path is unavailable, and so forth), the system can be programmed to run
specialized routines, which can determine whether the system should continue
functioning or whether the fault condition warrants a shutdown of the
application. For example, the system can be programmed to retrieve the fault
code of the failed module and make a determination, based on the type of fault,
as to whether to continue operating.
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Chapter 2
Features of the ControlLogix SIL 2 System
This ability of the controller to monitor the health of I/O modules in the system
and take appropriate action based on the severity of a fault condition gives the
user complete control of the application’s behavior. It is your responsibility to
establish the course of action appropriate to your safety application.
For more information on Fault Handling, see Chapter 8, Faults in the
ControlLogix System on page 99.
Data Echo Communication
Check
Output data echo allows the user to verify that an ON/OFF command from the
controller was received by the correct output module, and that the module will
attempt to execute the command to the field device.
During normal operation, when a controller sends an output command, the
output module receiving that command will ‘echo’ the output command back to
the controller upon its receipt. This verifies that the module has received the
command and will try to execute it. By comparing the requested state from the
controller to the data echo received from the module, you can validate that the
signal has reached the correct module and that the module will attempt to
activate the appropriate field-side device. The echo data is technically input data
from the output module and is located with the other output module data. For
example, an output module at local slot 3 will have Local:3:O and Local:3:I,
where 3:O are outputs and 3:I are inputs. Again, it is your responsibility to
establish the course of action appropriate for your safety application.
When used with standard ControlLogix output modules, the data echo validates
the integrity of communication up to the system-side of the module, but not to
the field-side. When you use this feature with diagnostic output modules, you can
verify the integrity from the controller to the output terminal on the module.
Diagnostic output modules contain circuitry that performs field-side output
verification. Field-side output verification informs you that commands received
by the module are accurately represented on the power side of the module’s
switching devices. In other words, for each output point, this feature confirms
that the output is ON when it is commanded to be ON or OFF when
commanded to be OFF.
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Features of the ControlLogix SIL 2 System
Chapter 2
Figure 15 - Output Module Behavior in the ControlLogix System
Output Commands from Controller
Standard ControlLogix I/O
Information
Additional Field-Side
Information Provided by
Diagnostic Output Modules
Data Echo validation from System-side
Field-side Output Verification, Pulse Test
Status Plus No Load Detection
Actuator
Pulse Test
Discrete diagnostic output modules feature called a pulse test can verify output
circuit functionality without actually changing the state of the actuator
connected to the output. An extremely short-duration pulse is directed to a
particular output on the module. The output circuitry will momentarily change
its state long enough to verify that it can change state on demand. The test pulse
is extremely fast (milliseconds), and typically does not affect actuators. Some
actuators may have electronic front ends and be capable of detecting these fast
pulses. You can disable pulse testing, if necessary.
Software
The location, ownership and configuration of I/O modules and controllers is
performed using RSLogix 5000 software. The software is used for all creation,
testing and debugging of application logic.
When using the programming software, you must remember these points:
• During normal control program (controller in Run mode):
– disconnect the programming terminal.
– set the key switch to the RUN position.
– remove the controller key from the key switch.
• Authorized personnel may change an application program, but only by
using one of the processes described in Changing Your
Application Program on page 97.
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Chapter 2
Features of the ControlLogix SIL 2 System
Communication
Several communication options are available for connecting with the
ControlLogix SIL 2 system and for the exchange of data within the SIL 2 system.
Communication Ports
A built-in serial port is available on 1756-L6x controllers for download or
visualization purposes only. Do not use the serial port for any exchange of safetyrelated data.
A built-in USB port is available for program upload and download on 1756-L7x
controllers.
ATTENTION: The USB port is intended for temporary local programming
purposes only and not intended for permanent connection.
WARNING: Do not use the USB port in hazardous locations.
Refer to the ControlLogix System User Manual, publication 1756-UM001, for
information on making communication connections.
ControlNet Network
The ControlNet network can be used to:
• provide communication between the controller and remote I/O chassis.
• form the basis for communication in duplex (redundant) configurations.
To schedule the ControlLogix ControlNet network, use RSNetWorx™ for
ControlNet software.
For more information on ControlNet networks, refer to ControlNet Network
Configuration Guide, publication CNET-UM001.
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Features of the ControlLogix SIL 2 System
Chapter 2
EtherNet/IP Network
An EtherNet/IP connection can be used to:
• download, monitor, and visualize the controller.
• connect to remote I/O chassis.
EtherNet/IP networks support messaging, produced/consumed tags, and
distributed I/O.
See EtherNet/IP Communication Modules on page 45 for details on using
EtherNet/IP modules in SIL 2 applications.
Electronic Keying of Modules
in SIL 2 Applications
If a module in your SIL 2-certified ControlLogix system is replaced, Exact Match
keying is recommended.
Exact Match keying requires all keying attributes, that is, Vendor, Product Type,
Product Code (catalog number), Major Revision, and Minor Revision, of the
physical module and the module created in the software to match precisely before
establishing communication. If any attribute does not match precisely, I/O
communication is not permitted with the module or with modules connected
through it, as in the case of a communication module.
For more information about electronic keying, see the ControlLogix Digital I/O
Modules User Manual, publication 1756-UM058.
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Chapter 2
Features of the ControlLogix SIL 2 System
Notes:
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Chapter
3
ControlLogix Controllers, Chassis, and Power
Supplies
ControlLogix Controllers
Topic
Page
ControlLogix Controllers
39
ControlLogix Chassis
41
ControlLogix Power Supplies
41
Recommendations for Using Power Supplies
42
The SIL 2-certified ControlLogix system is a user-programmed, solid-state
control system. These are examples of specific functions:
• I/O control
• Logic
• Timing
• Counting
• Report generation
• Communication
• Arithmetic
• Data file manipulation
The ControlLogix controller consists of a central processor, I/O interface, and
memory.
Operating Modes
The controller performs power-up and run-time functional tests. The tests are
used with user-supplied application programs to verify proper controller
operation.
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Chapter 3
ControlLogix Controllers, Chassis, and Power Supplies
A three-position keyswitch on the front of the controller governs ControlLogix
system operational modes. The following modes are available:
• Run
• Program
• Remote - This software-enabled mode can be Program or Run.
Figure 16 - Keyswitch in Run Mode
Logix557x
RUN FORCE SD
OK
REM PR
OG
RUN
1756-L6x
1756-L7x
When a SIL 2-certified ControlLogix application is operating in the Run mode,
the controller keyswitch must be in the RUN position and the key removed.
Requirements for Use
Consider these requirements when using a SIL 2-certified ControlLogix
controller:
• All components, such as input and output modules, for each safety
function must be owned by the specific controller performing the safety
function.
• When installing ControlLogix controller, refer to the user manual listed in
Additional Resources on page 11.
• There are currently separate firmware revisions for standard and redundant
operation. For more information, see Appendix B and the
Revision Release List available at http://www.ab.com from the Product
Certifications link.
For more information on the ControlLogix controllers, see the publications
listed in the Additional Resources on page 11.
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ControlLogix Controllers, Chassis, and Power Supplies
ControlLogix Chassis
Chapter 3
The ControlLogix 1756-Axx chassis provide the physical connections between
controllers and I/O modules. The chassis itself is passive and is not relevant to the
safety discussion because any physical failure would be unlikely under normal
environmental conditions and would be manifested and detected as a failure
within one or more of the active components.
When installing ControlLogix chassis, follow the instructions provided in the
product documentation.
ControlLogix Power Supplies
ControlLogix power supplies are certified for use in SIL 2 applications. No extra
configuration or wiring is required for SIL 2 operation of the ControlLogix
power supplies. If an anomaly occurs in the supplied voltages, the power supply
immediately shuts down.
All ControlLogix power supplies are designed to perform these tasks:
• Detect anomalies.
• Communicate to the controllers with enough stored power to allow for an
orderly and deterministic shutdown of the system, including the controller
and I/O modules.
IMPORTANT
If you are using any of the 1756-Px75 power supplies, with a 1756-L6x/B or
1756-L7x/B controller, you must use the Series B version of the
nonredundant power supplies, that is, 1756-Px75/B power supplies.
Redundant Power Supplies
ControlLogix redundant power supplies can be used in SIL 2-certified
applications. In a redundant power supply configuration, two power supplies are
connected to the same chassis.
The power supplies share the current load required by the chassis and an internal
solid state relay that can annunciate a fault. Upon detection of a failure in one
supply, the other redundant power supply automatically assumes the full current
load required by the chassis without disruption to installed devices.
The 1756-PSCA and 1756-PSCA2 redundant power supply chassis adapter
modules connect the redundant power supply to the chassis.
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Chapter 3
ControlLogix Controllers, Chassis, and Power Supplies
Recommendations for Using Power Supplies
When using SIL 2-certified ControlLogix power supplies:
• follow the information provided in the product’s installation instructions.
• wire the solid-state fault relay on each power supply from an appropriate
voltage source to an input point in the ControlLogix system so that the
application program can detect faults and react appropriately based on the
your application requirements.
For more information about installing ControlLogix chassis and power supplies,
see the publications listed in Additional Resources on page 11.
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Chapter
4
ControlLogix Communication Modules
Introduction to
Communication Modules
Topic
Page
Introduction to Communication Modules
43
ControlNet Modules and Components
44
EtherNet/IP Communication Modules
45
DeviceNet Scanner Module
45
Data Highway Plus - Remote I/O Module (1756-DHRIO)
45
SynchLink Module
45
General Requirements for Communication Networks
46
Peer-to-Peer Communication Requirements
46
Additional Resources
47
The communication modules in a SIL 2-certified ControlLogix system provide
communication bridges from a ControlLogix chassis to other chassis or devices
via the ControlNet and Ethernet networks. These communication modules are
available.
Network
SIL 2 Modules(2)
ControlNet
• 1756-CNB
• 1756-CNBR
• 1756-CN2
EtherNet/IP
•
•
•
•
•
DeviceNet(1)
Data Highway Plus™ – Remote I/O
SynchLink™
•
•
•
•
1756-EN2TR, series B
1756-EN2TR, series C
1756-EN2TRXT, series C
1756-EN3TR, series B(1)
1756-DNB
(1)
(1)
1756-ENBT, series A(1)
1756-EN2T, series C
1756-EN2T, series D(1)
1756-EN2TXT, series C
1756-EN2TXT, series D(1)
• 1756-CN2R
• 1756-CN2RXT
1756-DHRIO
1756-SYNCH
(1) Not for use in safety functions.
(2) Some catalog numbers have a K suffix. This indicates a version of the product that has conformal coating. These K versions
have the same SIL 2 certification as the non-K versions. For more information on which products have conformal coating go
to: http://ab.com.rockwellautomation.com/
ControlLogix communication modules can be used in peer-to-peer
communication between ControlLogix devices. The communication modules
can also be used for expansion of I/O to additional ControlLogix remote I/O
chassis.
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Chapter 4
ControlLogix Communication Modules
ControlNet Modules and
Components
The ControlNet bridge modules (catalog numbers 1756-CNB, 1756-CNBR,
1756-CN2, 1756-CN2R, and 1756-CN2RXT) provide communication
between any nodes properly scheduled on the ControlNet network.
ControlNet Cabling
For remote racks, a single RG6 coax cable is required for ControlNet
communication. Although it is not a requirement to use redundant media with
the 1756-CNBR or 1756-CN2R modules, it does provide higher system
reliability. Redundant media is not required for SIL 2 operation.
ControlNet Repeater
The following ControlNet repeater modules are approved for use in safety
applications up to and including SIL 2:
• 1786-RPCD, ControlNet Hub Repeater Module
• 1786-RPFS, Short-distance Fiber Repeater Module
• 1786-RPFM, Medium-distance Fiber Repeater Module
• 1786-RPFRL, Long-distance Fiber Repeater Module
• 1786-RPFRXL, Extra-long-distance Fiber Repeater Module
Use of the 1786-RPA adapter is required with all of the repeater modules listed.
Table 2 - For More Information About Repeater Modules
Topic
Publication Title
Publication Number
Planning for and installing ControlNet
repeater modules.
ControlNet Fiber Media Planning and
Installation Guide
CNET-IN001
Use of repeaters in safety applications.
TÜV Report 968/EZ
968/EX 135.06.12
ControlNet Module Diagnostic Coverage
All communication over the passive ControlNet media occur via CIP, which
verifies that at least one valid packet is seen during the greater of either 100 ms or
4 times the requested packet interval (RPI). If a valid packet is not seen during
this period, data transitions to the safe state.
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ControlLogix Communication Modules
EtherNet/IP Communication
Modules
Chapter 4
Use an EtherNet/IP communication module (catalog numbers 1756-EN2T,
1756-EN2TR, and 1756-EN2TXT) to:
• connect controller chassis to remote I/O.
• make connections for visualization purposes.
• establish connections between the programming terminal and controller.
IMPORTANT
Use of a 1756-EN2TR or 1756-EN2TRXT is required to achieve SIL 2 in your
application. See Figure 3 on page 18 for an example.
See the examples in Figure 5 on page 19, Figure 6 on page 20, and Figure 12 on
page 26.
DeviceNet Scanner Module
The 1756-DNB scanner module connects the controller to devices on a
DeviceNet™ network. You can use the 1756-DNB module to communicate only
nonsafety data to devices outside of the safety loop.
Data Highway Plus - Remote
I/O Module (1756-DHRIO)
The 1756-DHRIO module supports both Data Highway Plus™ and the
Remote I/O network of communication. You can use the 1756-DHRIO module
to communicate only nonsafety data to devices outside of the safety loop. For
example it may be used to communicate alarms to the Distributed Control
System (DCS).
SynchLink Module
The SynchLink™ module (catalog number 1756-SYNCH) is used for CST time
propagation between multiple chassis for event recording. The module can be
used only outside of the safety loop. It must not be used for any safety-related
activity in a SIL 2-certified ControlLogix system.
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Chapter 4
ControlLogix Communication Modules
General Requirements for
Communication Networks
Follow these requirements when using SIL 2-certified communication modules:
• When installing ControlLogix communication modules, carefully follow
the information provided in the module’s installation instructions.
• DH+ can be used for communication to Human-to-Machine Interfaces
(HMI) and for communicating with the nonsafety portion of the system.
For more information on using HMI, see Chapter 9, Use of Human-toMachine Interfaces on page 103.
• For controllers that are not part of the SIL 2 safety function, use listenonly connections to monitor SIL 2 I/O modules.
• You must not use the Quick Connect feature when using a Ethernet
communication for SIL 2 safety I/O.
• Only SIL 2 devices or other devices that provide non-interference should
write to SIL 2 controllers The only exception to this is the use of HMI
devices. For more information on how to use HMI in the safety loop, see
Chapter 9, Use of Human-to-Machine Interfaces on page 103.
Peer-to-Peer Communication
Requirements
Peer-to-peer communication via a ControlNet or EtherNet/IP network is
permitted when these requirements are met:
• Non-SIL 2 controllers can read data from SIL 2 controllers by directly
reading the data via a message instruction, or by consuming data from a
SIL 2 controller that is configured to produce data.
• Controllers within the safety loop can be configured to:
– consume safety data from other safety controllers within the safety
loop.
IMPORTANT
Always monitor connection status when consuming safety data from
another controller. Use this connection status to take appropriate
safety action, if necessary.
– consume non-safety data from outside the safety loop, such as a reset
signal.
– produce data to controllers outside the safety loop by using a write
message (MSG) or produced connections.
• Programming that verifies the correct reception of data must be used.
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Chapter 4
• Use of a device-level ring (DLR) is required to produce and consume SIL 2
data on an EtherNet/IP network. If you are not using the ring capability of
the 1756-EN2TR when producing or consuming SIL 2 safety data on an
EtherNet/IP network, you must use two independent data paths between
the SIL 2 devices. For example, to exchange SIL 2 data between two
ControlLogix SIL 2 controllers, you could use two produced connections
sending data to two consume connections. Each controller produces data
to the other.
Additional Resources
This table lists additional resources specific to the ControlLogix communication
modules.
Cat. No.
Module Description
User Manual
1756-CNB
1756-CN2
ControlNet Communication Module
CNET-UM001
1756-CNBR
1756-CN2R
Redundant ControlNet Communication Module
1756-DHRIO
Data Highway Plus - Remote I/O Communication Interface Module
1756-UM514
1756-DNB
DeviceNet Scanner Module
DNET-UM004
1756-ENBT
1756-EN2T
1756-EN2TR
1756-EN3TR
1756-EN2TRXT
1756-EN2TXT
Ethernet Communication Module
ENET-UM001
1756-RM
1756-RM2
Redundancy Module
1756-UM535
1756-SYNCH
SynchLink Module
1756-UM521
You can view or download Rockwell Automation publications at http://
www.rockwellautomation.com/literature/.
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Chapter 4
ControlLogix Communication Modules
Notes:
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Chapter
5
ControlLogix I/O Modules
Topic
Page
Overview of ControlLogix I/O Modules
49
Using 1756 Digital Input Modules
50
Using 1756 Digital Output Modules
52
Using 1756 Analog Input Modules
58
Using 1756 HART Analog Input Modules
65
Using 1756 Analog Output Modules
66
Using 1756 HART Analog Output Modules
71
IMPORTANT
Overview of ControlLogix
I/O Modules
The programming information and examples in this chapter are provided to
illustrate diagnostic and other logic-related principles that must be
demonstrated in SIL 2 application programs.
The principles and logic shown in this chapter can be encased in Add-On
Instructions for easier use.
If you are using a duplex configuration and certain I/O termination boards, the
programming explained in this chapter is available in Add-On Instructions.
These Add-On Instructions are certified by TÜV.
Refer to ControlLogix SIL 2 System Configuration Using SIL 2 Add-On
Instructions, publication 1756-AT012 for more information.
At the most basic level, there are two types of SIL 2-certified ControlLogix I/O
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 SIL 2-certified
ControlLogix I/O modules.
This figure shows the SIL 2-certified ControlLogix I/O modules. Each type,
digital or analog, is described in greater detail throughout the rest of this chapter.
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Chapter 5
ControlLogix I/O Modules
Figure 17 - Types of SIL 2-certified I/O Modules
SIL 2-Certified ControlLogix I/O Modules
1756 Digital I/O Modules
Diagnostic Digital
Modules
Input Modules,
including:
1756-IA8D
1756-IB16D
Output Modules,
including:
1756-OA8D
1756-OB16D
1756 Analog I/O Modules
Standard Digital Modules
Input Modules,
including:
1756-IA16I
1756-IB16I
1756-IB16ISOE
1756-IB32
1756-IH16ISOE
Output Modules,
including:
1756-OA16I
1756-OB16I
1756-OB16E
1756-OB32
1756-OB8EI
1756-OW16I
1756-OX8I
Input Modules,
including:
1756-IF16
1756-IF16H
1756-IF6CIS
1756-IF6I
1756-IF8
1756-IF8H
1756-IR6I
1756-IT6I
1756-IT6I2
Output Modules,
including:
1756-OF6CI
1756-OF6VI
1756-OF8
1756-OF8H
IMPORTANT: Some catalog numbers have a K suffix. This indicates a version of the product that has conformal coating. These K versions have the same SIL 2
certification as the non-K versions. For more information on which products have conformal coating go to: http://ab.com.rockwellautomation.com/
For SIL 2 compliance when installing ControlLogix I/O modules, follow the
procedures provided in the module’s installation instructions. For a full list of
installation instructions for SIL 2-certified modules, see Appendix B.
Using 1756 Digital
Input Modules
To achieve SIL 2, two digital input modules must be used, with field sensors
wired to channels on each module. The two channels must be compared by
software before reconciling the data.
ControlLogix digital input modules are divided into two categories:
• Diagnostic input modules
• Standard input modules
These modules share many of the same inherent architectural characteristics.
However, the diagnostic input modules incorporate features that allow
diagnosing of field-side failures. These features include broken-wire (that is, wireoff ) detection and, in the case of AC Diagnostic modules, loss of line power.
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Chapter 5
Requirements When Using Any ControlLogix Digital Input Module
Regardless of the type of ControlLogix input module used, you must follow these
general application requirements when applying these modules in a SIL 2
application:
• Ownership – The same controller must own both modules.
• Direct connection – Always use a direct connection with any SIL 2 CL
modules. You must not use rack optimized connections in a SIL 2
application.
• Separate input points – Wire sensors to separate input points on two
separate modules. The use of two digital input modules is required,
regardless of the number of field sensors.
• Field device testing – Test field devices by cycling them. The closer you
can get to the device being monitored to perform the test, the more
comprehensive the test will be.
• Proof tests – Periodically perform a system validation test. Manually or
automatically test all inputs to make sure they are operational and not
stuck in the ON or OFF state. Inputs must be cycled from ON to OFF or
OFF to ON. For more information, see Proof Tests on page 28.
Wiring ControlLogix Digital Input Modules
This diagram shows two examples of wiring digital inputs. In either case, the type
of sensors being used will determine whether the use of 1 or 2 sensors is
appropriate to fulfill SIL 2 requirements.
Figure 18 - ControlLogix Digital Input Module Wiring Example
+ Power
Input A1
Input B1
One-sensor Wiring Example
Sensor
Input A2
Optional Relay
contact or output
point to switch
supply voltage for
periodic
automated testing.
Input B2
Sensor
Two-sensor Wiring Example
Sensor
43366
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Chapter 5
ControlLogix I/O Modules
Application logic is used to compare input values for concurrence.
Figure 19 - Logic Comparing Input Values or States
Input A
Input B
No Faults
Actuator
The user program must also contain rungs to annunciate a fault in the event of a
sustained miscompare between two points.
Figure 20 - Rungs Annunciating a Fault
Input A
Input B
Timer
Input A
Input B
Timer preset in milliseconds to
compensate for filter time and
hardware delay differences.
Timer Done
Fault
Fault
Alarm to Operator
The control, diagnostics and alarming functions must be performed in sequence.
For more information on faults, see Chapter 8, Faults in the ControlLogix
System.
Using 1756 Digital
Output Modules
ControlLogix digital output modules are divided into two categories:
• Diagnostic output modules
• Standard output modules
These modules share many of the same inherent architectural characteristics.
However, the diagnostic output modules incorporate features that allow
diagnosing of field-side failures, including:
• No-Load (loss of load) reporting.
• Blown Fuse reporting.
• Output verify.
• Output pulse test.
To achieve SIL 2, a standard output module must be wired back to an input
module for monitoring. Diagnostic digital output modules provide their own
monitoring.
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Chapter 5
Requirements When Using ControlLogix Digital Output Modules
Wiring the two types of digital output modules differs, depending on your
application requirements (these wiring methods are explained in detail in later
sections). However, regardless of the type of ControlLogix output module used,
you must follow these general application requirements when applying these
modules in a SIL 2 application:
• Proof tests - Periodically perform a system validation test. Manually or
automatically test all outputs to make sure that they are operational and
not stuck in the ON or OFF state. Outputs must be cycled from ON to
OFF or OFF to ON. For more information, see Proof Tests on page 28.
• Examination of output data echo signal in application logic – The
application logic must examine the Data Echo value associated with each
output point to make sure that the requested ON/OFF command from
the controller was received and acted upon by the module.
In Figure 21, a timer begins to increment for any miscompare between the
controller’s output and the module’s Data Echo feedback. The discrepancy
timer must be set to accommodate the delay between the controller output
data and the module’s Data Echo response. The time value chosen needs to
consider various system RPIs and network latency. If a miscompare exists
for longer than that time, a fault bit is set.
Figure 21 - Data Echo Discrepancy Timer Logic
Application Logic
No Faults
Actuator
Output Bit
Data Echo
Timer
Output Bit
Data Echo
Fault
Secondary
Output
Timer Done
Fault
Fault
Alarm to Operator
The control, diagnostics and alarming functions must be performed in
sequence. For more information on faults, see Chapter 8, Faults in the
ControlLogix System.
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• Use of external relays to disconnect module power if output deenergized state is critical. To verify that outputs will de-energize, users
must wire an external relay or other measure, that can remove power from
the output module if a short or other fault is detected. See Figure 22 on
page 55 for an example method of wiring an external relay.
• Test outputs at specific times to make sure they are operating properly.
The method and frequency of testing is determined by the requirements of
the safety application. For more information on testing diagnostic module
outputs, see page 54. For more information on testing standard module
outputs, see page 56.
• For typical emergency shutdown (ESD) application outputs must be
configured to de-energize: When configuring any ControlLogix 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 Chapter 1, SIL Policy on
page 13.
• When wiring two digital output modules in series so that one may break
source voltage (as shown in Figure 26 on page 57), one controller must
own both modules.
Wiring ControlLogix Digital Output Modules
Diagnostic digital output modules and standard output modules have different
wiring considerations. Reference the module-type considerations that apply to
your system configuration.
Wiring Diagnostic Digital Output Modules
Diagnostic output modules have circuitry that is not included in standard output
modules. Because of this feature, you are not required to use an input module to
monitor output status, as is required with standard output modules.
Diagnostic output modules can be used as-is in a SIL 2 application. No special
wiring considerations need be employed other than the wiring of the external
relay or other measures to remove line power from the module in the event of a
fault to make sure outputs will de-energize if shorted.
In addition to referencing the Requirements When Using ControlLogix Digital
Output Modules on page 53 for limited high demand applications, testing of
output modules (that is, the user turns the outputs ON and OFF to verify proper
operation) should be executed once every eight hours. Note that high demand
applications are limited to 10 demands per year for ControlLogix SIL 2 systems.
For more information on performing the pulse test, see the ControlLogix Digital
I/O Modules User Manual, publication 1756-UM058.
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Figure 22 - ControlLogix Diagnostic Output Module Wiring
V-/L2
V+/L1
Secondary
Output
V+/L1
This normally-open contact (held closed) must represent
the healthy operation of the controller and safety I/O
modules. Safety I/O status can be restricted to inputs
directly affecting outputs on the specific module, or this
contact can represent the healthy status of all safety
inputs and the controller. The module used to control
this relay must follow SIL 2 output guidelines. This
module must also be considered during PFD analysis for
each safety function. We recommend the use of a
recognized safety relay or contactor.
Output
Relays may also be
included as shown in
position A to interrupt
power on a per point
basis.
Actuator
43365
Figure 23 - Diagnostic Output Logic
Application Logic
Output Fault
Actuator
Data Echo
Actuator
Timer
Data Echo
Actuator
Fault
Secondary
Output
Timer Done
Fault
Fault
Alarm to
Operator
Output Fault contact must represent module and channel diagnostics.
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Wiring Standard Digital Output Modules
When using standard (non-diagnostic) output modules, you must wire each
output to its field device and also to a system input to monitor the output’s
performance. To verify output performance, use one of these methods:
• Write logic to test the output’s ability to turn ON and OFF at power-up.
• At the proof test interval, force the output ON and OFF and use a
voltmeter to verify output performance.
For limited high demand applications, testing of output modules (that is, the user
turns the outputs ON and OFF to verify proper operation) should be executed
once every eight hours. Note that high demand applications are limited to 10
demands per year for ControlLogix SIL 2 systems.
See Requirements When Using ControlLogix Digital Output Modules on
page 53.
Figure 24 - ControlLogix Standard Output Module Wiring
Standard Isolated
Output Module
V-/L2
V+/L1
Standard Isolated
Input Module
Wire output point to
input point to verify
the correct state of
the output.
Secondary
Output
V+/L1
This normally-open contact (held closed) must
represent the healthy operation of the controller
and safety I/O modules. Safety I/O status can be
restricted to inputs directly affecting outputs on
the specific module, or this contact can represent
the healthy status of all safety inputs and the
controller. The module used to control this relay
must follow SIL 2 output guidelines. This module
also must be considered during PFD analysis for
each safety function.
Output
Input
Actuator
V-/L2
43363
Write the application logic to generate a fault in the event of a miscompare
between the controller, the actual output state, and the monitored input.
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Figure 25 - Comparison Logic for Requested versus Actual Output
Application Logic
Output Fault
Actuator
Timer must be preset in
milliseconds to
accommodate
communication times of
echo signal and filter time
of input.
Monitoring Input
Output Data Echo
Timer
Monitoring Input
Output Data Echo
Fault
Secondary
Output
Timer Done
Fault
Fault
Alarm to
Operator
Output Fault contact must represent module and channel diagnostics.
The control, diagnostics, and alarming functions must be performed in sequence.
For more information on faults, see Chapter 8, Faults in the ControlLogix
System on page 99.
You can also wire two isolated, standard outputs in series to critical actuators. In
the event that a failure is detected, the outputs from each of the output modules
must be set to OFF to make sure the field devices de-energize. Figure 26 shows
how to wire two isolated, standard outputs in series to critical actuators.
Figure 26 - ControlLogix Standard Output Module Wiring with Two Modules
Standard Isolated
Output Module #1
V-/L2
Standard Isolated
Input Module
Standard Isolated
Output Module #2
Wire output point to
input point to verify
the correct state of the
output.
V+/L1
V+/L1
V+/L1
Output
Output
Input
Actuator
V-/L2
43364
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Using 1756 Analog
Input Modules
There are a number of general application considerations that you must make
when using analog input modules in a SIL 2 application. The following section
describes those considerations specific to the use of analog input modules.
To achieve SIL 2, two analog input modules are required. Field sensors must be
wired to channels on each module and compared within a deadband. Whether
one or two field sensors are required is dependent on the Probability of Failure on
Demand (PFD) value of the sensor.
Conduct Proof Tests
Periodically perform a system validation test. Manually or automatically test all
inputs to make sure that they are operational. Field signal levels should be varied
over the full operating range to make sure that the corresponding channel data
varies accordingly. For more information, see Proof Tests on page 28.
Calibrate Inputs
Analog input modules should be calibrated periodically, as their use and
application requires. ControlLogix I/O modules ship from the factory with a
highly accurate level of calibration. However, because each application is
different, you are responsible for making sure your ControlLogix I/O modules
are properly calibrated for your specific application.
You 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, you can determine a tolerance band of accuracy for a specific
application. You 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, you 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 three years to verify
the accuracy of the input signal and avoid nuisance application shutdowns.
Use the Floating Point Data Format
ControlLogix analog input modules perform on-board alarm processing to
validate that the input signal is within the proper range. These features are only
available in Floating Point mode. To use the Floating Point Data format, select
the Floating Point Data format in the Module Properties dialog box.
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Chapter 5
Program to Respond to Faults Appropriately
When programming the SIL 2 system, verify that your program examines the
appropriate module fault, channel fault, and channel status bits and responds by
initiating the appropriate fault routine.
Each module communicates the operating status of each channel to the controller
during normal operation. Application logic must examine the appropriate bits to
initiate a fault routine for a given application. For more information on faults, see
Chapter 8, Faults in the ControlLogix System on page 99.
Program to Compare Analog Input Data
When wiring sensors to two input channels on different modules, the values from
those channels must be compared to each other within the program for
concurrence within an acceptable range for the application, before an output is
actuated. Any miscompare between the two inputs outside the programmed
acceptable range must be annunciated as a fault.
In Figure 27, 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 inputs are working properly.
The input’s OK bit preconditions 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.
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Figure 27 - Comparison Logic for Two Analog Inputs
Inputs OK
Timer
MULT
Range
Tolerance%
Delta
ADD
Delta
Input 1
High Limit
SUB
Delta
Input 1
Low Limit
LIM
Low Limit
Input 2
High Limit
Inputs OK
Timer Done
Analog Inputs
Faulted
Analog Inputs Faulted
Alarm to Operator
The control, diagnostics and alarming functions must be performed in sequence.
For more information on faults, see Chapter 8, Faults in the ControlLogix
System on page 99.
Configure Modules
When using identical modules, configure the modules identically, that is, by using
the same RPI, filter values, and so on.
When using different modules for improved diversity, make sure the module’s
scaling of data does not introduce error or fault conditions.
Specify the Same Controller as the Owner
The same controller must own both analog input modules.
You must use Analog Inputs Faulted as a safety status/permissive in respective
safety-related outputs.
Wiring ControlLogix Analog Input Modules
The wiring diagrams shown in this section apply to applications requiring two
transmitters. The type of transmitter along with the application requirements
will determine whether one or two transmitters are required.
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Chapter 5
In general, good design practice dictates that each of the two transmitters must be
wired to input terminals on separate modules such that the channel values may be
validated by comparing the two within an acceptable range. Special consideration
must be given in applying this technique, depending on the type of module being
used.
Wiring the Single-Ended Input Module in Voltage Mode
Make sure you:
• review the considerations in Using 1756 Analog Input Modules on
page 58.
• use the correct documentation (listed in Additional Resources on page 11)
to wire the module.
• tie all (-) leads of the transmitters together when operating in single-ended
Voltage mode.
Figure 28 shows how to wire an analog input for use in Voltage mode.
Figure 28 - ControlLogix Analog Input Module Wiring in Voltage Mode
Ch0 +
Ch0 +
(+)
(–)
Ch0 –
Voltage
Transmitter A
Ch0 –
(+)
(–)
Voltage
Transmitter B
43368
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Figure 29 shows how to wire a SIL 2 transmitter to two analog input modules
configured for voltage mode.
Figure 29 - ControlLogix Analog Input Module Wiring in Voltage Mode
Ch0 +
Ch0 +
(+)
SIL 2 Transmitter Voltage
Output Source
Ch0 –
Ch0 –
(–)
Figure 30 - Analog Input Wiring Example with Termination Boards
Analog Input Module A
Input Values from Field Devices
Analog Input Module B
Input Values from Field Devices
All configured for 0...5V operation.
All configured for 0...5V operation.
Solid-state switch controlled
by DC output.
1492 Cable to 1756-IF16,
Module A
DIP Switch for Sensor
Wiring
1492 Cable to 1756-IF16,
Module B
Reference Voltages
Precision 249 :
Resistor
Terminal Block 1,
Row C
Terminal Block 2,
Row C
Terminal Block 1,
Row B
Terminal Block 2,
Row B
Two-wire Transmitter
Two-wire Transmitters Operating in
4...20 mA Current Mode
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Output from 1756-OB16D Module Pair
Trigger Reference Tests = 0 (Off)
ControlLogix I/O Modules
Chapter 5
Wiring the Single-ended Input Module in Current Mode
Make sure you:
• review the considerations in Using 1756 Analog Input Modules on
page 58.
• use the correct documentation (listed in Additional Resources on page 11)
to wire the module.
• place devices correctly in the 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)
Figure 31 and Figure 32 show how to wire an analog input for use in Current
mode.
Figure 31 - ControlLogix Analog Input Module Wiring in Current Mode
Ch0 +
Ch0 +
Current
Source A
Ch0 –
Ch0 –
Current
Source B
43369
Figure 32 - ControlLogix Analog Input Module Wiring for Isolated Channels (in Current mode)
Ch0 +
Ch0 –
Ch0 +
SIL 2 Transmitter Current
Output Source
Ch0 –
If you use single-ended channels, use a 1492-TAIFM16-F-3 termination board
and two 1492-ACABLE010UA cables to split the current sensor into two singleended channels configured for Voltage mode.
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Wiring the Thermocouple Input Module
Make sure you:
• review the considerations in Using 1756 Analog Input Modules on
page 58.
• use the correct documentation (listed in Additional Resources on page 11)
to wire the module.
• 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 33 on page 64 shows how to wire the 1756-IT6I module.
Figure 33 - ControlLogix Analog Thermocouple Module Wiring
Ch0 +
Ch0 +
Thermocouple A
RTN
RTN
Thermocouple B
43370
Wiring the RTD Input Module
Make sure you:
• review the considerations in Using 1756 Analog Input Modules on
page 58.
• use the correct documentation (listed in Additional Resources on page 11)
to wire the module.
• use two sensors. RTDs cannot be wired in parallel without severely
affecting their accuracy.
Figure 34 shows how to wire the 1756-IR6I module.
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Figure 34 - ControlLogix Analog RTD Module Wiring
Ch0 A
Ch0 A
RTD A
Ch0 B
Ch0 B
RTN
RTN
RTD B
43371
Using 1756 HART Analog
Input Modules
The Highway Addressable Remote Transducer (HART) analog modules should
be used according to the same considerations as other analog input modules.
IMPORTANT
HART protocol must not be used for safety-related data.
Wiring the HART Analog Input Modules
Make sure you:
• review the considerations in Using 1756 Analog Input Modules on
page 58.
• use the correct documentation (listed in Additional Resources on page 11)
to wire the module.
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Figure 35 - HART Input Analog Module Wiring
Ch0 +
Ch0 +
Sensor
Ch0 -
Ch0 -
Sensor
Using 1756 Analog Output
Modules
There are a number of general application considerations that you must make
when using analog output modules in a SIL 2 application.
A single analog output module, along with an analog input module for
monitoring is required to achieve SIL 2.
The following sections describe those considerations specific to the use analog
output modules.
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Chapter 5
Considerations for Using Analog Output Modules
IMPORTANT
It is strongly recommended that you do not use analog outputs to execute
the safety function that results in a safe state. Analog output modules are
slow to respond to an ESD command and are therefore not recommended
for use ESD output modules.
The use of digital output modules and actuators to achieve the ESD deenergized state is recommended.
Conduct Proof Tests
Periodically perform a system validation test. Manually or automatically test all
outputs to make sure that they are operational. Field signal levels should be varied
over the full operating range to make sure that the corresponding channel data
varies accordingly. For more information, see Proof Tests on page 28.
Calibrate Outputs
Analog output modules should be calibrated periodically, as their use and
application requires. ControlLogix I/O modules ship from the factory with a
highly accurate level of calibration. However, because each application is
different, you are responsible for making sure your ControlLogix I/O modules
are properly calibrated for your specific application.
You 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, you can determine a tolerance band of accuracy for a
specific application. You 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, you 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 signal and avoid nuisance application shutdowns.
Use the Floating Point Data Format
ControlLogix analog output modules perform on-board alarm processing to
validate that the input signal is within the proper range. These features are only
available in Floating Point mode. To use the Floating Point Data format, select
the Floating Point Data format in the Module Properties dialog box.
Program to Respond to Faults Appropriately
When programming the SIL 2 system, verify that your program examines the
appropriate module fault, channel fault, and channel status bits and responds by
initiating the appropriate fault routine.
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Each module communicates the operating status of each channel to the controller
during normal operation. Application logic must examine the appropriate bits to
initiate a fault routine for a given application. For more information on faults, see
Chapter 8, Faults in the ControlLogix System on page 99.
Configure Outputs to De-energize in ESD Applications
For typical emergency shutdown (ESD) applications, outputs must be configured
to de-energize. When configuring any ControlLogix 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 Chapter 1, SIL Policy on page 13.
Monitor Channel Status
You must wire each analog output to an actuator and then back to an analog
input to monitor the output’s performance, as shown in Figure 37. The
application logic must examine the analog input (feedback value) associated with
each analog output to make sure that the output from the controller was received
correctly at the actuator. The analog output value must be compared to the
analog input that is monitoring the output to make sure the value is within an
acceptable range for the application.
In the ladder diagram in Figure 36, a user-defined percentage of acceptable
deviation (that is, tolerance) is applied to the configured range of the analog
input and output 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 Echo is
then compared to these limits to determine if the output is 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 Echo miscompare
for longer than the preset value, a fault is registered with a corresponding alarm.
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Figure 36 - Monitoring an Analog Output with an Analog Input
Outputs OK
Timer
MULT
Range
Tolerance%
Delta
ADD
Delta
SUB
Delta
Monitoring input
Monitoring input
High Limit
Low Limit
LIM
Low Limit
Output Echo
High Limit
Outputs OK
Fault
Secondary
Output
Timer Done
Outputs Faulted
Outputs Faulted
Alarm to Operator
The control, diagnostics, and alarming functions must be performed in sequence.
Specify the Same Controller as the Owner
The same controller must own both analog modules.
Wiring ControlLogix Analog Output Modules
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
Make sure you:
• review the considerations in Considerations for Using Analog Output
Modules on page 67.
• Use the correct documentation (listed in Additional Resources on
page 11) to wire the module.
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Figure 37 shows how to wire the 1756-OF8 module for use in Voltage mode.
Figure 37 - ControlLogix Analog Output Module Wiring in Voltage Mode
Analog Output Module
Analog Input Module
(+)
(+)
Actuator
Secondary
Output
(–)
This normally-open relay is controlled by
the status of the rest of the ControlLogix
system. If a short-circuit or fault occurs on
the module, the relay can disconnect
power to the module. The module used to
control this relay must follow SIL 2 output
guidelines. This module also must be
considered during PFD analysis for each
safety function.
The relay used should be a signal-grade
relay using bifurcated or similar grade
contacts. The relay can be located in a
position to remove power to a single
actuator, or can remove power to multiple
actuators depending on the granularity
needed.
(–)
43377
Wiring the Analog Output Module in Current Mode
Make sure you:
• review the considerations in Considerations for Using Analog Output
Modules on page 67.
• use the correct documentation (listed in Additional Resources on page 11)
to wire the module.
• place devices correctly in the 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 (each
module output is 250 :).
Figure 38 shows how to wire the 1756-OF8 module for use in Current mode.
Figure 38 - ControlLogix Analog Output Module Wiring in Current Mode
Analog Output Module
Analog Input Module
(+)
(+)
(–)
(–)
This normally-open relay is controlled by the status of
the rest of the ControlLogix system. If a short-circuit or
fault occurs on the module, the relay can disconnect
power to the module. The module used to control this
relay must follow SIL 2 output guidelines. This module
also must be considered during PFD analysis for each
safety function.
Actuator
Secondary
Output
43376
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The relay used should be a signal-grade relay using
bifurcated or similar grade contacts. The relay can be
located in a position to remove power to a single
actuator, or can remove power to multiple actuators
depending on the granularity needed.
ControlLogix I/O Modules
Using 1756 HART Analog
Output Modules
Chapter 5
The Highway Addressable Remote Transducer (HART) analog modules should
be used according to the same considerations as other analog output modules. For
an illustration of how to wire the HART analog output modules, see Wiring the
HART Analog Output Modules on page 71.
IMPORTANT
HART protocol must not be used for safety-related data.
Wiring the HART Analog Output Modules
Make sure you:
• review the considerations in Wiring ControlLogix Analog Output
Modules on page 69.
• use the correct documentation (listed in Appendix B) as a reference when
wiring the module.
Figure 39 - HART Output Analog Module Wiring
Input Module
Output Module
Output Module
Ch0+
Ch0+
Ch0+
Ch0-
Ch0-
Ch0-
Actuator
Ch1+
Actuator
Ch1-
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Notes:
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Chapter
6
FLEX I/O Modules
Topic
Overview of FLEX I/O Modules
Page
Overview of FLEX I/O Modules
73
Using 1794 Digital Input Modules
73
Using 1794 Digital Output Module
75
Using 1794 Analog Input Modules
77
Using 1794 Analog Output Modules
84
There are two types of SIL 2-certified FLEX I/O modules:
• Digital I/O modules
• Analog 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.
Using 1794 Digital
Input Modules
To achieve SIL 2, two digital input modules must be used, with field sensors
wired to channels on each module. The two channels must be compared by
software before reconciling the data.
Requirements When Using FLEX I/O Digital Input Modules
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 SIL 2 application:
• Proof tests - Periodically a system validation test must be performed.
Manually, or automatically, test inputs to make sure that all inputs are
operational and not stuck in the ON or OFF state. Inputs must be cycled
from ON to OFF or OFF to ON.
• Wire sensors to separate input points on two separate modules that are on
different network nodes.
• Configuration parameters (for example, RPI, filter values) must be
identical between the two modules.
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• The same controller must own both modules.
• Monitor the network status bits for the associated module and ensure that
appropriate action is invoked via the application logic by these status bits.
Wiring FLEX I/O Digital Input Modules
The wiring diagrams in Figure 40 show two methods of wiring the digital input
module. In either case, you must determine whether the use of 1 or 2 sensors is
appropriate to fulfill SIL 2 requirements.
Figure 40 - ControlLogix Digital Input Module Wiring
One-Sensor Wiring Example
Input 1
24VDC SINK INPUT
0
1 2
+24V dc
Input 2
1794-IB16
24VDC SINK INPUT
3 4 5 6 7 8 9 10 11 12 13 14 15
0
1 2
Optional relay contact
to switch line voltage
for periodic automated
testing
1794-IB16
3 4 5 6 7 8 9 10 11 12 13 14 15
Input
COM
+24V
SIL2 SENSOR
Two-Sensor Wiring Example
Input 1
24VDC SINK INPUT
0
1 2
Input 2
1794-IB16
24VDC SINK INPUT
3 4 5 6 7 8 9 10 11 12 13 14 15
0
1 2
1794-IB16
3 4 5 6 7 8 9 10 11 12 13 14 15
Input
COM
+24V
1
SENSOR
1
Note 1: Both sensors are monitoring the same safety application.
SENSOR
43366
Application logic can compare input values or states for concurrence.
Figure 41 - Compare Input Values
Input A
Input B
Actuator
The user program must also contain rungs to annunciate a fault in the event of a
sustained miscompare between two points.
Figure 42 - Annunciate a Fault
Input A
Input B
Timer
Input A
Input B
Timer preset in milliseconds to
compensate for filter time and
hardware delay differences.
Timer Done
Fault
Fault
Alarm to Operator
The control, diagnostics and alarming functions must be performed in sequence.
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FLEX I/O Modules
Using 1794 Digital
Output Module
Chapter 6
To achieve SIL 2, the output module must be wired back to an input module for
monitoring.
Requirements When Using FLEX I/O Digital Output Modules
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 SIL 2 application:
• Proof tests- Periodically a System Validation test must be performed.
Manually, or 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 ON to OFF or OFF to ON.
Figure 43 - Testing Outputs
Application Logic
Output Fault
Actuator
Output Bit
Monitoring Input
Timer
Output Bit
Monitoring Input
Timer done
Fault
Fault
Alarm to Operator
The control, diagnostics and alarming functions must be performed in
sequence.
• Use external relays to disconnect actuator power if output deenergization is critical. To make sure outputs will de-energize, you 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.
• Wire sensors to separate input points on two separate modules that are on
different network nodes.
• Monitor the network status bits for the associated module and make sure
that appropriate action is invoked via the application logic by these status
bits.
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Chapter 6
FLEX I/O Modules
Wiring FLEX I/O Digital Output Modules
When using standard output modules, you must wire an output to an actuator
and then back to an input to monitor the output’s performance.
Figure 44 - FLEX I/O Standard Output Module Wiring
Standard Digital Output Module
COM
Wire output point to input
point to verify the correct
state of the output.
+24V
C
Standard Digital Input Module
B
CE P
C IN INP
IB
A
COM
24V DC
Output
B
Actuator
43363
IMPORTANT: Other configurations are possible as long they are SIL 2 approved.
Install a relay in position A or B. This relay is controlled by another output in the ControlLogix/FLEX I/O 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-OW8) can be used for this purpose when it is connected to a different 1794-ACN15 or 1794-ACNR15
ControlNet Adapter module.
Write application logic so that it generates 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 43 on page 75).
The control, diagnostics and alarming functions must be performed in sequence.
You 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 45 on page 77.
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Chapter 6
Figure 45 - ControlLogix/FLEX I/O Standard Output Module Wiring with an Isolated Relay Module
Standard Digital
Output Module
COM
Isolated Relay Output
Module
+24V
C
CE P
B
C
CE P
B
Standard Digital
Input Module
Wire output point to
input point to verify
the correct state of the
output.
COM
+24V
Output
Output
IB
C IN INP
Actuator
43364
Note 1: An external relay can be replaced with an isolated relay module that is mounted in another FLEX I/O rail.
Using 1794 Analog
Input Modules
To achieve SIL 2, two analog input modules are required. Field sensors must be
wired to channels on each module and compared within a deadband. Whether
one or two field sensors are required is dependent on the Probability of Failure on
Demand (PFD) value of the sensor.
Requirements When Using FLEX I/O Analog Input Modules
You must follow these general application considerations when applying these
modules in a SIL 2 application:
• Proof tests. Periodically a System Validation test must be performed.
Manually, or 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.
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FLEX I/O Modules
• 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, you are responsible for making sure
their FLEX I/O modules are properly calibrated for their specific
application.
You 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 for a specific application. You 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, you
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 miscompare between the two
inputs outside the programmed acceptable range must be annunciated as a
fault.
In Figure 46 on page 79, 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.
The input’s OK bit preconditions 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.
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Figure 46 - Logic for Comparing Analog Input Data
Inputs OK
Timer
MULT
Range
Tolerance %
Delta
ADD
Delta
Input 1
High Limit
LIM
Low Limit
Input 2
High Limit
SUB
Delta
Input 1
Low Limit
Inputs OK
Timer Done
Inputs Faulted
Inputs Faulted
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.
The same controller must own both modules.
Wire sensors to separate input points on two separate modules that are on
different network nodes.
Monitor the network status bits for the associated module and make sure
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 network nodes.
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FLEX I/O Modules
Wiring FLEX I/O Analog Input Modules
The wiring diagrams in this section show two methods of wiring the analog input
module. In either case, you must determine whether the use of 1 or 2 sensors is
appropriate to fulfill SIL 2 requirements.
Figure 47 - FLEX I/O Analog Input Module Wiring
One-Sensor Wiring Example
Input 1
Input 2
Input
COM
+24V
Two-Sensor Wiring Example
SIL2 SENSOR
Input 1
Input 2
Input
COM
+24V
SENSOR
SENSOR
1
1
43366A
Note 1: Both sensors are monitoring the same safety application.
Wiring the Single-ended Input Module in Voltage Mode
In addition to following the Requirements When Using FLEX I/O Analog Input
Modules on page 77, make sure you use the correct documentation to wire the
module.
Figure 48 - FLEX I/O Analog Input Module Wiring in Voltage Mode
Analog Input
1794-IE8
+ Voltage
Transmitter A
1794-TB3
Analog Input
1794-IE8
Voltage
Transmitter B
Analog Input
1794-IF4I
+
-
Analog Input
1794-IF4I
1794-TB3
Voltage
Transmitter A
80
1794-TB3
+ -
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
+
-
Voltage
Transmitter B
1794-TB3
FLEX I/O Modules
Chapter 6
Wiring the Single-ended Input Module in Current Mode
In addition to following the Requirements When Using FLEX I/O Analog Input
Modules on page 77, before wiring the module, consider the following
application guideline:
• Place 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)
Figure 49 - FLEX I/O Analog Input Wiring in Current Mode
1794-IE8
Analog Input
1794-IE8
Analog Input
1794-IE8
1794-TB3
1794-TB3
Current
Source A
RET
Current
Source B
Analog Input
1794-IF4I
Analog Input
1794-IF4I
1794-TB3
1794-TB3
Current
Source A
RET
RET
Current
Source B
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RET
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FLEX I/O Modules
Wiring the Thermocouple Input Module
In addition to following the Requirements When Using FLEX I/O Analog Input
Modules on page 77 and before wiring the module, consider the following
application guideline:
• Wire to the 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 50 - FLEX I/O Analog Thermocouple Module Wiring
Thermocouple
Input Module
1794-IT8
Thermocouple
Input Module
1794-TB3T
1794-TB3T
+
+
-
-
Thermocouple/
RTD/mV
Input Module
1794-IRT8
Thermocouple/
RTD/mV
Input Module
1794-TB3G
82
1794-IRT8
1794-TB3G
+
+
-
-
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1794-IT8
FLEX I/O Modules
Chapter 6
Wiring the RTD Input Module
In addition to following the Requirements When Using FLEX I/O Analog Input
Modules on page 77 and before wiring the module, consider the following
application guideline:
• RTDs cannot be wired in parallel without severely affecting their accuracy.
Two sensors must be used.
Figure 51 - FLEX I/O Analog RTD Module Wiring
RTD
Input Module
1794-IR8
RTD
Input Module
1794-TB3T
1794-IR8
1794-TB3T
3-wire RTD
Thermocouple/
RTD/mV
Input Module
1794-IRT8
Thermocouple/
RTD/mV
Input Module
1794-TB3G
1794-IRT8
1794-TB3G
4-wire RTD
Two-, three-, or four-wire RTDs can be used as applicable to the associated RTD input module.
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Chapter 6
FLEX I/O Modules
Using 1794 Analog
Output Modules
A single analog output module, along with an analog input module for
monitoring is required to achieve SIL 2.
IMPORTANT
We strongly recommended that you do not use analog outputs to execute
the safety function that results in a safe state. Analog output modules are
slow to respond to an ESD command and are therefore not recommended
for use ESD output modules.
The use of digital output modules and actuators to achieve the ESD deenergized state is recommended.
Requirements When Using FLEX I/O Analog Output Modules
Follow these general application considerations when applying the analog output
modules in a SIL 2 application:
• Proof tests - Periodically a System Validation test must be performed.
Manually, or 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.
• Calibrate outputs periodically, as necessary. FLEX I/O modules ship
from the factory with a highly accurate level of calibration. However,
because each application is different, you are responsible for making sure
their FLEX I/O modules are properly calibrated for their specific
application.
You 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. You 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, you
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.
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Chapter 6
• Wire outputs back to inputs and examine output data feedback signal.
You 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 52, 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.
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Chapter 6
FLEX I/O Modules
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 52 - Monitoring an Analog Output with an Analog Input
Outputs OK
Timer
MULT
Range
Tolerance %
Delta
ADD
Delta
SUB
Delta
Monitoring input
Monitoring input
High Limit
Low Limit
LIM
Low Limit
Output Echo
High Limit
Outputs OK
Timer Done
Outputs Faulted
Outputs Faulted
Alarm to Operator
The control, diagnostics and alarming functions must be performed in
sequence.
• When wiring two analog output modules in the same application, make
sure:
– Both modules use identical configuration.
– The same controller owns both modules.
• The two analog output modules must be on separate FLEX I/O rails.
They must not share the same FLEX adapter.
• Monitor the network status bits for the associated module and make sure
that appropriate action is invoked via the application logic by these status
bits.
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Chapter 6
Wiring FLEX I/O Analog Output Modules
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
You must wire analog outputs to an actuator and then back to an analog input to
monitor the output performance.
Figure 53 - Analog Input Module Wiring Example
1794-OE4
1794-IE8
Analog Input
Module
Analog Output
Module
V RET
1794-TB3
1794-TB3
+ Actuator
_
1794-OF4I
1794-IF4I
Isolated Analog
Output Module
Isolated Analog
Input Module
V RET
1794-TB3
1794-TB3
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
+ Actuator
_
87
Chapter 6
FLEX I/O Modules
Wiring the Analog Output Module in Current Mode
In addition to following the Requirements When Using FLEX I/O Analog
Output Modules on page 84, consider the following application guideline before
wiring the module in Current mode:
• Place 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.
Figure 54 - Analog Output Wiring Example
1794-OE4
1794-IE8
Analog Input
Module
Analog Output
Module
+ _
1794-TB3
1794-TB3
Actuator
1794-OF4I
1794-IF4I
Isolated Analog
Output Module
+ _
Isolated Analog
Input Module
1794-TB3
1794-TB3
Actuator
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Chapter
7
Requirements for Application Development
Software for SIL 2Related Systems
Topic
Page
Software for SIL 2-Related Systems
89
SIL 2 Programming
89
Programming Languages
90
Programming Options
90
Security
90
Basics of Application Program Development and Testing
91
Functional Specification Guidelines
92
Creating the Application Program
93
Forcing
94
Checking the Application Program
94
Verify Download and Operation
95
Commissioning Life Cycle
96
Changing Your Application Program
97
The application software for the SIL 2-related automation system is created using
the programming tool, that is, RSLogix 5000 software, according to
IEC 61131 3.
The application program has to be created by using the programming tool and
contains the specific equipment functions that are to be carried out by the
ControlLogix system. Parameters for the operating function are also entered into
the system using the programming software.
SIL 2 Programming
The safety concept of the SIL 2 ControlLogix system assumes the following:
• The programming software is installed correctly.
• Control system hardware is installed in accordance with product
installation guidelines.
• User application code (user program) uses common and good design
practices.
• A test plan is documented and adhered to, including well-understood
proof test requirements and procedures.
• A well-designed validation process is defined and implemented.
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Requirements for Application Development
For the initial start-up of a safety-related ControlLogix system, the entire system
must be checked by a complete functional test. After a modification of the
application program, the modified program or logic must be checked.
For more information on how users should handle changes to their application
program, see Changing Your Application Program on page 97.
Programming Languages
It is good engineering practice to keep safety-related logic as simple and easy to
understand as possible. The preferred language for safety-related functions is
ladder logic, followed by function block. Structured text and sequential function
chart are not recommended for safety-related functions.
Programming Options
Pre-programmed SIL 2 I/O Add-On Instructions can be used in RSLogix 5000
software, version 20 or later. If you choose to use Add-On Instructions, refer to
ControlLogix SIL 2 System Configuration Using SIL 2 Add-On Instructions,
publication 1756-AT012.
Using the SIL 2 Add-On Instructions greatly simplifies the programming
required for a SIL 2 system. However, these instructions may not be suitable for
use in all SIL 2 applications and system configurations. You need to evaluate the
suitability of a SIL 2 Add-On Instruction that is used in a safety-related function.
All Add-On Instructions require the use of hardware termination boards.
Security
The user must define what measures are to be applied for the protection against
manipulation.
In the ControlLogix system and in the programming software, protection
mechanisms are available that help prevent unintentional or unauthorized
modifications to the safety system:
• The following tools may be employed for security reasons in a
SIL 2-certified ControlLogix application:
– Logix CPU Security
– Routine Source Protection
– FactoryTalk® AssetCentre
Each of these features or products offers different security features,
including password protection, at varying levels of granularity throughout
the application. The description of these tools is too large in scope to list in
detail here. Contact your local Rockwell Automation representative for
more information.
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Chapter 7
• The controller keyswitch must be in the RUN position and the key
removed during normal operating conditions.
Figure 55 - Keyswitch in Run Mode
Logix557x
RUN FORCE SD
OK
REM PR
OG
RUN
1756-L6x
1756-L7x
• In RSLogix 5000 software, version 18 and later, you can set tags to be
standard, read-only, or constant values. Read-only blocks external devices
(for example, HMIs and other controllers) from changing a tag. Constants
block everything, including user logic from changing a tag value. All SIL 2
safety-related tags should be set to read-only. Where possible, configure
SIL 2 safety tags as constant value tags.
The requirements of the safety and application standards regarding the
protection against manipulations must be observed. The authorization of
employees and the necessary protection measures are the responsibility of the
individuals starting and maintaining the SIL 2 safety system.
Basics of Application
Program Development
and Testing
The application program is intended to be developed by the system integrator
and/or user. The developer must consider general procedures for programming
ControlLogix SIL 2 applications listed below (this does not require independent
third party review).
• Specification of the SIL 2 safety control function, including the following:
– Specifications
– Flow and timing charts
– Engineering diagrams
– Sequence charts
– Program description
– Program review process
• Writing the application program
• Checking by independent reviewer
• Verification and validation
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Requirements for Application Development
All application logic must be independently reviewed and tested. To facilitate
reviews and reduce unintended responses, developers should limit the set of
instructions to basic Boolean/ladder logic (such as examine On/Off, Timers,
Counters, and so on) whenever possible. This set should include instructions that
can be used to accommodate analog variables, such as the following:
• Limit tests
• Comparisons
• Math instructions
For more information, see Proof Tests on page 28.
Functional Specification
Guidelines
You must create a specification for your control function. Use this specification to
verify that program logic correctly and fully addresses your application’s
functional and safety control requirements. The specification may be presented
in a variety of formats, depending on your application.
The specification must include a detailed description that includes the following
(if applicable):
• Sequence of operations
• Flow and timing diagrams
• Sequence charts
• Program description
• Program print out
• Written descriptions of the steps with step conditions and actuators to be
controlled, including the following:
– Input definitions
– Output definitions
– I/O wiring diagrams and references
– Theory of operation
• Matrix- or table form of stepped conditions and the actuators to be
controlled, including the sequence and timing diagrams
• Definition of marginal conditions, for example, operating modes,
EMERGENCY STOP, and others
The I/O-portion of the specification must contain the analysis of field circuits,
that is, the type of sensors and actuators.
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Chapter 7
Sensors (digital or analog)
• Signal in standard operation (dormant current principle for digital sensors,
sensors OFF means no signal)
• Determination of redundancies required for SIL levels
• Discrepancy monitoring and visualization, including the user’s diagnostic
logic
Actuators
• Position and activation in standard operation (normally OFF)
• Safe reaction or positioning when switching OFF
• Discrepancy monitoring and visualization, including the user’s diagnostic
logic
Creating the
Application Program
Consider the following when developing the application program logic.
Logic and Instructions
The logic and instructions used in programming the application must be:
• easy to understand.
• easy to trace.
• easy to change.
• easy to test.
• well-documented.
Program Language
You must implement simple, easy to understand:
• ladder.
• other IEC 61131-3-compliant language.
• function blocks with specified characteristics.
We use ladder, for example, because it is easier to visualize and make partial
program changes with this format.
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Requirements for Application Development
Program Identification
The application program is clearly identified by one of the following:
• Name
• Date
• Revision
• Any other user identification information
SIL Task/Program Instructions
The user application should contain a single SIL task composed of programs and
routines. The SIL 2 task must be the controller’s top priority task and the userdefined watchdog must be set to accommodate the SIL 2 task.
Forcing
IMPORTANT
Motion-related functions are not allowed and must not be used.
IMPORTANT
You must dedicate a specific task for safety-related functions and set that task
to the highest priority (1). SIL 2 safety logic and logic intended for use in nonSIL 2 functions must be separate, or everything in the task containing safety
must be treated as safety-related.
The following rules apply to forcing in a project:
• You must remove forces on all SIL 2 tags and disable forcing before
beginning normal operation for the project.
• You must not force SIL 2 tags after validation is performed and during
controller operation in Run mode.
IMPORTANT
Checking the Application
Program
Forcing must not be used during normal operation, as well as during final
system test and validation.
To check safety-related application logic for adherence to specific safety
functions, you must generate a suitable set of test cases that cover the safety
specification. The set of test cases needs to be well-written and filed as the test
specification.
Suitable tests must also be generated for the numeric evaluation of formulas.
Equivalent range tests are acceptable. These are tests within defined value ranges,
at the limits, and outside the defined value ranges. The test cases must be selected
to prove the correctness of the calculation. The necessary number of test cases
depends on the formula used and must comprise critical value pairs.
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Chapter 7
However, active simulation with sources cannot be omitted as this is the only
means of detecting correct wiring of the sensors and actuators to the system.
Furthermore, this is the only means of testing the system configuration. Users
should verify the correct programmed functions by forcing I/O or by manual
manipulation of sensors and actuators.
Verify Download
and Operation
Verify the download of the application program and its proper operation. A
typical technique is to upload the completed program file and perform a compare
of that file against what is stored in the programming terminal.
IMPORTANT
Do not use memory cards to automatically transfer the safety application. After
a safety application is downloaded, you must verify the download.
The AutoFlash firmware feature is not supported for SIL-2 safety applications
and must not be used.
IMPORTANT
If the controller has a USB port, it is intended for temporary local programming
purposes only and not intended for permanent connection.
These are typical steps for performing a verification in RSLogix 5000 software.
1. With the programming software not running, rename the offline project.
2. Start the programming software, upload the controller project, and save it.
3. Open the compare tool and select both files.
4. Start the compare operation.
5. Review the compare output results and verify that everything matches
without error.
Project documentation differences will likely exist.
6. Save the compare results as part of the verification process.
7. Delete the upload file.
8. Rename the original project file (change back) to the original project name
to maintain project documentation.
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Figure 56 shows the steps required during application program development,
debugging and commissioning.
Commissioning Life Cycle
Figure 56 - Application Development Life Cycle
Generate Functional
Specification
Create Flow
Diagram
Create Timing
Diagrams
Establish Sequence of
Operations
Develop Project
Online
Develop Project
Offline
Review Program with
Independent Party
Download to
Controller
Develop Test Plan
Perform Validation
Testing on all Logic
Yes
Tests Pass?
No
Verification
okay?
Make more online edits &
accept edits or make more
offline edits and download to
CTR
Begin Normal Project
Operation
Download to
Controller
No
Make project
changes
Determine what logic has
been Changed or Affected
Perform Validation Testing
on all Changed or Affected
Logic
Finish the Validation
Test1
1
Secure PADT
96
You must periodically repeat the validation test (also known as proof tests) to make sure module inputs and outputs are functioning properly and as commanded by the
application programming. For more information on proof tests for I/O modules, see Chapter 1, SIL Policy on page 13.
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Requirements for Application Development
Changing Your
Application Program
Chapter 7
The following rules apply to changing your application program in
RSLogix 5000 software:
IMPORTANT
You cannot make program edits while the program is online if the
changes prevent the system from executing the safety function or if
alternative protection methods are not in place.
• Program edits are not recommended and should be limited. For example,
minor changes such as changing a timer preset or analog setpoint are
allowed.
• Only authorized, specially-trained personnel can make program edits.
These personnel should use all supervisory methods available, for example,
using the controller keyswitch and software password protections.
• Anyone making data or programming edits to an operational system
assumes the central safety responsibility while the changes are in progress.
These personnel must also maintain safe application operation.
• Prior to making any program edits, you must perform an impact analysis
by following the safety specification and other lifecycle steps described in
Figure 56 on page 96 as if the edits were an entirely new program.
• Users must sufficiently document all program edits, including:
– authorization.
– impact analysis.
– execution.
– test information.
– revision information.
• Multiple users cannot edit a program from multiple programming
terminals simultaneously.
• Changes to the safety application software–in this case, RSLogix 5000
software– must comply with IEC 61511 standard on process safety section
11.7.1 Operator Interface requirements.
• When the ControlLogix controller keyswitch is in the RUN position
(controller is in Run mode), you cannot make online edits.
• You can edit the relay ladder logic portion of the safety program using one
of the following methods described in Table 3.
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97
Chapter 7
Requirements for Application Development
Table 3 - Methods of Changing Your Application Program
Method
Required Steps
Controller
Keyswitch
Position
Key Points to this Method
Offline
Perform the tasks described in the flow chart in Figure 56 on page 96.
PROG
You must re-validate the entire application
before returning to normal operation.
Online
1. Turn the controller key to the REM position.
2. Use the Online Edit Toolbar to start, accept, test and assemble your edits. The toolbar is shown
below.
REM
The project remains online but operates in the
remote Run mode. When edits are completed,
you are required to validate only the changed
portion of the application program.
We recommend that online edits be limited to
minor program modifications such as setpoint
changes or ladder logic rung additions,
deletions and modifications.
IMPORTANT:This option to change the
application program is available for changes to
relay ladder logic only. You cannot use this
method to change function block
programming.
For more detailed information on how to edit
ladder logic while online, see the Logix5000
Controllers Quick Start, publication
1756-QS001.
Start
pending
rung edit.
Accept
pending rung
edits.
Assemble
program
edits.
a. Click the start pending rung edits button
Test program
edits.
Untest
program
edits.
. A copy is made of the rung you want to edit.
b. Change your application program as needed. At this point, the original program is still active in
the controller. Your program changes are made in the copied rungs. Changes do not affect the
outputs until you test program edits in step d.
c. Click the accept pending rung edits button
. Your program changes are verified and
downloaded to the controller. The controller now has the changed program and the original
program. However, the controller continues to execute the original program. You can see the
state of the inputs, and changes do not affect the outputs.
d. Click the test program edits button
.
e. Click Yes to test the edits.
Changes are now executed and affect the outputs; the original program is no longer
executed. However, if you are not satisfied with the result of testing the edits,
you can discard the new program by clicking on the untest program edits button
if necessary. If you untest the edits, the controller returns to the original program.
f. Click the assemble program edits button
.
g. Click Yes to assemble the edits. The changes are the only program in the controller, and the
original program is discarded.
3. Perform a partial proof test of the portion of the application affected by the program edits.
4. Turn the controller key back to the RUN position to return the project to Run mode. We
recommend you upload the new program to your programming terminal to help ensure
consistency between the application in the controller and on the programming terminal.
5. Remove the key.
IMPORTANT
98
If any changes are needed to the program in the safety loop, they must be
done in accordance with IEC 61511-1, paragraph 11.7.1.5, which states:
‘The Safety Instrumentation System (SIS) operator interface design shall be
such as to prevent changes to SIS application software. Where safety
information needs to be transmitted from the basic process control system
(BPCS) to the SIS then systems should be used that can selectively allow
writing from the BPCS to specific SIS variables. Equipment or procedures
should be applied to confirm the proper selection has been transmitted and
received by the SIS and does not compromise the safety function of the SIS.’
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Chapter
8
Faults in the ControlLogix System
Topic
Page
Detecting and Reacting to Faults
99
Module Fault Reporting for Any ControlLogix or FLEX I/O Module
100
Checking Keyswitch Position with GSV Instruction
100
Examining an 1756 Analog Input Module’s High Alarm
101
Additional Resources
102
In addition to providing information on module fault reporting, this chapter
explains two example conditions that will generate a fault in a SIL 2-certified
ControlLogix system:
• Keyswitch changing out of Run mode
• High alarm condition on an analog input module
Detecting and Reacting
to Faults
The ControlLogix architecture provides many ways of detecting and reacting to
faults in the system.
• Various device objects can be interrogated to determine the current
operating status.
• Modules provide run-time status of their operation and of the process that
is executing.
• You can configure a ControlLogix system to identify and handle faults,
including such tasks as:
– developing a fault routine.
– creating a user-defined major fault.
– monitoring minor faults.
– developing a power-up routine.
See the Logix5000 Controllers Common Procedures Programming
Manual, publication 1756-PM001, for more information.
It is your responsibility to determine what data is most appropriate for your
application to initiate a shutdown sequence.
To help handle faults, make sure you have completed the input (see Checklist
TIP
for SIL Inputs on page 140) and output (see Checklist for SIL Outputs on
page 142) checklists for their application.
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Chapter 8
Faults in the ControlLogix System
Module Fault Reporting for
Any ControlLogix or FLEX I/O
Module
You must verify that all components in the system are operating properly. This
can be accomplished in ladder logic through the use of the Get System Value
instruction (GSV) and an examination of the MODULE Object’s Entry Status’
attribute for a running condition.
An example of how this might be done is shown in Figure 57. This method, or
something similar, must be used to interrogate the health of each I/O module in
the system.
Figure 57 - Example of Checking a Module’s Health in Ladder Logic
AND
NEQ
Mask Off Lower 12 Bits
of Value
Check Entry Status to
make sure module is
running.
GSV
Obtain MODULE Object’s
Entry Status
Fault
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.Slot1StatusBits” is defined as
follows:
• Node 3 is the name given to the adapter, in this example, a
1794-ACNR15.
• I indicates the Input file.
• SlotStatusBits is a 32-bit value, where the lower 8 bits correspond to a
FLEX I/O module, as shown.
Module 7
Checking Keyswitch Position
with GSV Instruction
Module 6
Module 5
Module 4
Module 3
Module 2
Module 1
Module 0
The following rungs generate a fault if the keyswitch on the front of the
controller is switched from the RUN position.
Figure 58 - Keyswitch State (Operation mode) Change Logic
GSV
Class: CONTROLLERDEVICE
Attribute: STATUS
Destination: KEYSTATE
KEYSTATE.13
Fault
Fault
Alarm to Operator
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Faults in the ControlLogix System
Chapter 8
In Figure 58 on page 100, the Get System Value (GSV) instruction interrogates
the STATUS attribute of the CONTROLLERDEVICE object and stores the
result in a word called KEYSTATE, where bits 12 and 13 define the state of the
keyswitch as shown in Table 4.
Table 4 - Keyswitch State Bits
Bit 13
Bit 12
Description
0
1
Keyswitch in Run position
1
0
Keyswitch in Program position
1
1
Keyswitch in Remote position
If bit 13 is ever ON, then the keyswitch is not in the RUN position. Examining
bit 13 of KEYSTATE for an ON state will generate a fault.
It is your responsibility to determine appropriate behavior when a fault is present.
For more information on the accessing the CONTROLLERDEVICE object, see
the Logix5000 Controllers General Instructions Reference Manual, publication
1756-RM003.
Examining an 1756 Analog
Input Module’s High Alarm
ControlLogix analog modules perform processing and comparison of field data
values right on the module, allowing for easy examination of status bits to initiate
a fault.
For example, the 1756-IF8 module can be configured with user-defined alarm
values that, when exceeded, will set a status bit on the module, which is then sent
back to the controller. You can examine the state of these bits to initiate a fault as
shown in Figure 59.
Figure 59 - High Alarm Bit to Trigger Fault
Ch1HAlarmA
Ch1HAlarmB
Module A
Module B
Fault
Fault
Alarm to
Operator
In the example above, the High Alarm bits for channels 1 and 2 are being
examined for a condition to initiate a fault. During operation, as the analog input
module processes analog signals from the field sensors, if the value exceeds the
user-defined value for High Alarm, the alarm bit is set and a fault is declared.
It is your responsibility to determine appropriate behavior when a fault is present.
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101
Chapter 8
Faults in the ControlLogix System
Additional Resources
The ControlLogix architecture provides the user many ways of detecting and
reacting to faults in the system. Various device objects can be interrogated to
determine the current operating status. Additionally, modules provide run-time
status of their operation and of the process.
Resource
Description
Logix5000 Controllers General Instructions Reference
Manual, publication 1756-RM003
Provides information on how to use specific instructions
to get and set controller system data stored in device
objects
Logix5000 Controllers Common Procedures Programming
Manual, publication 1756-PM001
Provides information on controller fault codes, including
major and minor codes and on creating fault and powerup routines
ControlLogix Analog I/O Modules User Manual,
publication 1756-UM009
ControlLogix Digital I/O Modules User Manual,
publication 1756-UM058
102
Provides information on accessing modules’ run-time
operational and process status
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Chapter
9
Use of Human-to-Machine Interfaces
Precautions
Topic
Page
Precautions
103
Accessing Safety-related Systems
103
You must exercise precautions and implement specific techniques on HMI
devices. These precautions include, but are not restricted to the following:
• Limited access and security
• Specifications, testing and validation
• Restrictions on data and access
• Limits on data and parameters
For more information on how HMI devices fit into a typical SIL loop, see
Figure 10 on page 24.
Use sound techniques in the application software within the HMI and controller.
Accessing Safety-related
Systems
HMI- related functions consist of two primary activities: reading and
writing data.
Reading Parameters in Safety-related Systems
Reading data is unrestricted because reading doesn’t affect the operation or
behavior of the safety system. However, the number, frequency, and size of the
data being read can impact controller performance. To avoid safety-related
nuisance trips, use good communication practices to limit the impact of
communication processing on the controller. Do not set read rates to the fastest
rate possible.
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Chapter 9
Use of Human-to-Machine Interfaces
Changing Safety-related Parameters in SIL-rated Systems
A parameter change in a safety-related loop via an external (that is, outside the
safety loop) device (for example, an HMI) is allowed only with the following
restrictions:
• Only authorized, specially-trained personnel (operators) can change the
parameters in safety-related systems via HMIs.
• The operator who makes changes in a safety-related system via an HMI is
responsible for the effect of those changes on the safety loop.
• You must clearly document variables that are to be changed.
• You must use a clear, comprehensive, and explicit operator procedure to
make safety-related changes via an HMI.
• Changes can only be accepted in a safety-related system if the following
sequence of events occurs.
a. The new variable must be sent twice to two different tags; that is, both
values must not be written to with one command.
b. Safety-related code, executing in the controller, must check both tags
for equivalency and make sure they are within range (boundary checks).
c. Both new variables must be read back and displayed on the HMI
device.
d. Trained operators must visually check that both variables are the same
and are the correct value.
e. Trained operators must manually acknowledge that the values are
correct on the HMI screen that sends a command to the safety logic,
which allows the new values to be used in the safety function.
In every case, the operator must confirm the validity of the change before
they are accepted and applied in the safety loop.
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Use of Human-to-Machine Interfaces
Chapter 9
• Test all changes as part of the safety validation procedure.
• Sufficiently document all safety-related changes made via HMI, including
the following:
–
–
–
–
–
Authorization
Impact analysis
Execution
Test information
Revision information
• Changes to the safety-related system, must comply with IEC 61511
standard on process safety section 11.7.1 Operator Interface requirements.
• The developer must follow the same sound development techniques and
procedures used for other application software development, including the
verification and testing of the operator interface and its access to other
parts of the program. The controller application software should set up a
table that is accessible by the HMI and limits access to required data points
only.
• Similar to the controller program, the HMI software needs to be secured
and maintained for SIL-level compliance after the system has been
validated and tested.
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105
Chapter 9
Use of Human-to-Machine Interfaces
Notes:
106
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Appendix
A
Reaction Times of the ControlLogix System
Topic
Page
Local Chassis Configuration
107
Remote Chassis Configuration
108
Calculating Worst-case Reaction Time
108
The calculation formulas in this chapter can be used to calculate the worst-case
reaction times for a given change in input or fault condition and the
corresponding output action.
Local Chassis Configuration
Figure 60 shows an example system with digital or analog modules where the
following occurs:
• Field signal changes state.
• The data is transmitted to the controller.
• The controller runs its program scan and reacts to the data change.
• The controller transmits data to the output module.
• The output module processes data from the controller and turns the
output device on or off.
Figure 60 - Local Chassis Configuration of Digital or Analog Modules
Input Module
Controller
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Output Module
107
Appendix A
Reaction Times of the ControlLogix System
Remote Chassis
Configuration
Figure 61 shows an example system where the following occurs:
• Input data changes on the input module.
• The data is transmitted to the controller via the network communication
modules.
• The controller runs its program scan and reacts to the data change,
including sending new data to the output module via the network
communication modules.
• The output module behavior changes based on the new data received from
the controller.
Figure 61 - Remote Chassis Configuration of Digital or Analog Modules
Controller
Calculating Worst-case
Reaction Time
Network
Communication
Module
Network
Communication
Module
Input
Module
Input
Module
Output Output
Module Module
The formulas for calculating worst-case reaction times with no system faults or
errors differ slightly for digital or analog I/O modules, as shown in the following
sections.
For Digital Modules
Use this formula to determine worst-case reaction time for digital modules in
local or remote configurations:
Worst-Case Reaction Time with no faults or errors =
(Input Module Delay + Input Filter Time) + (Input Module RPI x 4/8/16… t100 ms)(1) +
(SIL 2 Task Period + SIL 2 Task Watchdog) + (Output Module RPI x 4/8/16… t100 ms)(1) +
(Output Module Delay).
Module delay times are listed in the ControlLogix I/O Modules Specifications
Technical Data, publication 1756-TD002.
(1) Multiply the module RPI by 4, then 8, then 16, and so on, until the result is at least 100 ms.
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Reaction Times of the ControlLogix System
Appendix A
Input filter time is configurable via the Configuration tab on the Module
Properties dialog box in the programming software.
• If the safe state in your application is low, use the On -> Off Input Filter
Time.
• If the safe state in your application is high, use the Off -> On Input Filter
Time.
Figure 62 - Digital Module Configuration
Module RPI is configurable via the Connection tab.
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109
Appendix A
Reaction Times of the ControlLogix System
For Analog Modules
Use this formula to determine worst-case reaction time for analog modules in
local or remote configurations:
Worst-Case Reaction Time with no faults or errors =
(Real Time Sample (RTS) Rate) +
(Input Module RPI x 4/8/16… t100 ms)(1) + (SIL 2 Task Period + SIL 2 Task Watchdog) +
(Output Module RPI x 4/8/16… t100 ms)(1) + (Output Module Delay).
Filter time and RTS are configurable via the Configuration tab on the Module
Properties dialog box in the programming software. Module RPI is configurable
via the Connection tab.
Figure 63 - Analog Module Configuration
Refer to the ControlLogix Analog I/O Module User Manual, publication
1756-UM009, for information on setting filter and RTS values.
(1) Multiply the module RPI by 4, then 8, then 16, and so on, until the result is at least 100 ms.
110
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Appendix
B
SIL 2-certified ControlLogix System Components
System components listed in this appendix are certified according to IEC 61508
2010 Edition 2, unless noted in the following tables.
Use only the series versions listed in Appendix C. These tables list publications
related to these components. Publications are available from Rockwell
Automation by visiting http://www.rockwellautomation.com/literature.
Table 5 - SIL 2-certified ControlLogix Components - Hardware
Cat. No.(1)
Description
1756-A4, 1756-A7
1756-A10, 1756-A13,
1756-A17
ControlLogix chassis
1756-PA75(2)
ControlLogix AC power supply
1756-PB75(2)
ControlLogix DC power supply
1756-PA75R
ControlLogix AC redundant power supply
1756-PB75R
ControlLogix DC redundant power supply
1756-PA72
ControlLogix AC power supply
1756-PB72
ControlLogix DC power supply
1756-PC75
ControlLogix DC power supply
1756-PH75
ControlLogix DC power supply
1756-PSCA(3)
1756-PSCA2
(3)
Related Documentation
1756-IN005
ControlLogix redundant power supply chassis adapter module
ControlLogix redundant power supply chassis adapter module
(1) Some catalog numbers have a K suffix. This indicates a version of the product that has conformal coating. These K versions have the
same SIL 2 certification as the non-K versions. For more information on which products have conformal coating go to
http://ab.com.rockwellautomation.com/
(2) The 1756-PA75/A and 1756-PB75/A power supplies are no longer available. However, if your existing SIL 2 application uses these
power supplies, they are SIL 2 certified.
(3) Existing systems that use the 1756-PSCA and 1756-PSCA2 are SIL 2-certified. However, when implementing new SIL 2-certified
systems or upgrading existing systems, we recommend that you use the 1756-PSCA2 module if possible.
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
111
Appendix B
SIL 2-certified ControlLogix System Components
Table 6 - SIL 2-certified ControlLogix Components - 1756 Nonredundant Controllers, I/O, and
Communication Modules
Cat. No.(1)
1756-L61(2) (3)
ControlLogix 2 MB controller
1756-L62(2) (3)
ControlLogix 4 MB controller
1756-L63(2) (3)
ControlLogix 8 MB controller
1756-L71(2)
ControlLogix 2 MB controller
(2)
ControlLogix 4 MB controller
1756-L73(2)
ControlLogix 8 MB controller
1756-L74(2)
ControlLogix 16 MB controller
1756-L72
1756-L75
112
Description
(2)
Related
Documentation
1756-UM001
ControlLogix 32 MB controller
1756-IA16I
ControlLogix AC isolated input module
1756-IA8D
ControlLogix AC diagnostic input module
1756-IB16D
ControlLogix DC diagnostic input module
1756-IB16I
ControlLogix DC isolated input module
1756-IB32
ControlLogix DC input module
1756-IB16ISOE
ControlLogix Sequence of Events module
1756-IH16ISOE
ControlLogix Sequence of Events module
1756-OA16I
ControlLogix AC isolated output module
1756-OA8D
ControlLogix AC diagnostic input module
1756-OB16D
ControlLogix DC diagnostic output module
1756-OB16E
ControlLogix DC electronically-fused output module
1756-OB16I
ControlLogix DC isolated output module
1756-OB32
ControlLogix DC output module
1756-OB8EI
ControlLogix DC isolated output module
1756-OW16I
ControlLogix isolated relay output module
1756-OX8I
ControlLogix isolated relay output module
1756-IF8
ControlLogix analog input module
1756-IF16
ControlLogix analog input module
1756-IF6I
ControlLogix Isolated analog input module
1756-IF6CIS
ControlLogix Isolated analog input module
1756-IF8H
ControlLogix HART analog input module
1756-IF16H
ControlLogix HART analog input module
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
1756-UM058
1756-UM528
1756-UM058
1756-UM009
1756-UM533
SIL 2-certified ControlLogix System Components
Appendix B
Table 6 - SIL 2-certified ControlLogix Components - 1756 Nonredundant Controllers, I/O, and
Communication Modules
Cat. No.(1)
Description
Related
Documentation
1756-IR6I
ControlLogix RTD input module
1756-IT6I
ControlLogix Thermocouple input module
1756-IT6I2
ControlLogix enhanced Thermocouple input module
1756-OF8
ControlLogix analog output module
1756-OF6CI
ControlLogix isolated analog output module
1756-OF6VI
ControlLogix isolated analog output module
1756-OF8H
ControlLogix HART analog output module
1756-CNB(4)
ControlLogix ControlNet communication module
1756-CN2
ControlLogix ControlNet communication module
1756-CN2R
ControlLogix redundant media ControlNet communication module
1786-RPFS
ControlNet short-distance fiber repeater module
1786-IN012
1786-RPFM
ControlNet medium-distance fiber repeater module
1786-IN011
1786-RPFRL
ControlNet long-distance fiber repeater module
1786-RPFRXL
ControlNet extra-long-distance fiber repeater module
1756-UM009
1756-UM533
CNET-IN005
CNET-UM001
1786-IN003
1786-RPA
ControlNet repeater adapter
1786-IN013
1786-RPCD
ControlNet Hub repeater module
1786-IN001
1756-EN2TR Series B
1756-EN2TR Series C
ControlLogix redundant media EtherNet/IP communication module ENET-IN002
ControlLogix redundant media EtherNet/IP communication module ENET-UM001
1756-EN2T Series C
ControlLogix EtherNet/IP communication module
(1) Some catalog numbers have a K suffix. This indicates a version of the product that has conformal coating. These K versions have the
same SIL 2 certification as the non-K versions. For more information on which products have conformal coating go to
http://ab.com.rockwellautomation.com/
(2) Use of any series B controller requires the use of the series B versions of the 1756-Px75 power supplies.
(3) Certified according to IEC 61508 1999 Edition 1.
(4) Specified ControlNet repeaters may be used in SIL 2 applications. See Chapter 4, ControlLogix Communication Modules for more
information.
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Appendix B
SIL 2-certified ControlLogix System Components
Table 7 - SIL 2-certified ControlLogix Components - 1756 Redundancy System Components
Cat. No.(1)
Description
1756-L61(2) (3)
ControlLogix 2 MB controller
1756-L62(2) (3)
ControlLogix 4 MB controller
1756-L63
(2) (3)
ControlLogix 8 MB controller
1756-L71
(2)
ControlLogix 2 MB controller
1756-L72(2)
ControlLogix 4 MB controller
1756-L73(2)
ControlLogix 8 MB controller
1756-L74(2)
ControlLogix 16 MB controller
1756-L75(2)
ControlLogix 32 MB controller
1756-CNB
ControlLogix ControlNet communication module
Related
Documentation
1756-UM001
1756-CNBR
ControlLogix redundant media ControlNet communication module
1756-CN2
ControlLogix ControlNet communication module
1756-CN2R
ControlLogix redundant media ControlNet communication module
1756-EN2T Series C
ControlLogix EtherNet/IP communication module
1756-EN2TR Series B
ControlLogix redundant media EtherNet/IP communication module
CNET-IN005
CNET-UM001
ENET-IN002
ENET-UM001
1756-EN2TR Series C
(1) Some catalog numbers have a K suffix. This indicates a version of the product that has conformal coating. These K versions have the
same SIL 2 certification as the non-K versions. For more information on which products have conformal coating go to
http://ab.com.rockwellautomation.com/
(2) Use of any series B controller requires the use of the series B versions of the 1756-Px75 power supplies or the redundant power
supplies, that is, the 1756-Lx75R power supplies.
(3) Certified according to IEC 61508 1999 Edition 1.
Table 8 - SIL 2-certified ControlLogix-XT System Components
Cat. No.
Description
1756-A4LXT
1756-A5XT,
1756-A7XT
1756-A7LXT
ControlLogix-XT chassis
1756-PAXT
1756-PBXT
ControlLogix-XT power supply
1756-CN2RXT
ControlLogix-XT ControlNet communication module
CNET-IN005
CNET-UM001
ENET-IN002
ENET-UM001
1756-IN005
1756-EN2TXT Series C
ControlLogix-XT EtherNet/IP communication module
1756-EN2TRXT Series C
ControlLogix-XT EtherNet/IP communication module for redundant
systems
1756-L63XT(1)
ControlLogix-XT controller
1756-L73XT
ControlLogix-XT controller
(1) Certified according to IEC 61508 1999 Edition 1.
114
Related
Documentation
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
1756-UM001
SIL 2-certified ControlLogix System Components
IMPORTANT
\
Appendix B
ControlLogix-XT™ modules use the same firmware as traditional
ControlLogix components. When obtaining firmware for ControlLogix-XT
modules, download and use the firmware specific to each module.
For example, if you are using a 1756-EN2TXT module in your system, use
SIL 2-certified firmware for the 1756-EN2T module.
For more information about ControlLogix-XT module firmware revisions,
see the firmware release notes specific to the module. ControlLogix-XT
module release notes are available at:
http://www.rockwellautomation.com/literature or
http://www.rockwellautomation.com/support/.
Table 9 - FLEX I/O Components For Use in the SIL 2 System
Cat. No.(1)
Description
1794-ACN15
FLEX I/O ControlNet single media adapter
1794-ACNR15
FLEX I/O ControlNet redundant media adapter
Related Documentation(2)
1794-IN128
1794-ACNR15XT
FLEX I/O-XT™ ControlNet redundant media adapter
1794-AENT
FLEX I/O EtherNet/IP communication adapter
1794-AENTR
FLEX I/O EtherNet/IP redundant communication
adapter
1794-AENTRXT
FLEX I/O-XT EtherNet/IP redundant communication
adapter
1794-IB16
FLEX I/O input module
1794-IN093
1794-IB16XT
FLEX I/O-XT input module
1794-IN124
1794-IB10XOB6
FLEX I/O input/output module
1794-IN083
1794-IB10XOB6XT
FLEX I/O-XT input/output module
1794-IN124
1794-OB16
FLEX I/O output module
1794-IN094
1794-OB16P
FLEX I/O protected output module
1794-IN094
1794-OB16PXT
FLEX I/O-XT protected output module
1794-IN124
1794-OB8EP
FLEX I/O electronically-fused output module
1794-IN094
1794-OB8EPXT
FLEX I/O-XT electronically-fused output module
1794-IN124
1794-OW8
FLEX I/O relay output module
1794-OW8XT
FLEX I/O-XT relay output module
1794-IE8
FLEX I/O analog input module
1794-IN100
1794-UM002
1794-IF4I
FLEX I/O isolated analog input module
1794-IN038
1794-UM008
1794-IF4IXT
FLEX I/O-XT isolated analog input module
1794-IN129
1794-UM008
1794-IF4ICFXT
FLEX I/O-XT isolated analog input module
1794-IN130
1794-UM008
1794-IF2XOF2I
FLEX I/O isolated analog input/output module
1794-IN039
1794-UM008
1794-IF2XOF2IXT
FLEX I/O-XT isolated analog input/output module
1794-IN129
1794-UM008
1794-OE4
FLEX I/O analog output module
1794-IN100
1794-UM002
1794-OF4I
FLEX I/O isolated analog output module
1794-IN037
1794-UM008
1794-IT8
FLEX I/O Thermocouple input module
1794-IN021
1794-UM007
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
1794-IN082
1794-IN131
1794-IN019
115
Appendix B
SIL 2-certified ControlLogix System Components
Table 9 - FLEX I/O Components For Use in the SIL 2 System
Cat. No.(1)
Description
Related Documentation(2)
1794-IR8
FLEX I/O RTD input module
1794-IR8XT
FLEX I/O-XT RTD input module
1794-IN021
1794-UM004
1794-IRT8
FLEX I/O Thermocouple/RTD input module
1794-IRT8XT
FLEX I/O-XT Thermocouple/RTD analog input module
1794-IJ2
FLEX I/O counter module
1794-IJ2XT
FLEX I/O-XT counter module
1794-IP4
FLEX I/O counter module
1794-IN064
1794-UM016
1794-IE4XOE2XT
FLEX I/O-XT analog input/output module
1794-IN125
1794-IE8XT
FLEX I/O-XT analog input module
1794-IN125
1794-OE4XT
FLEX I/O-XT analog output module
1794-IN125
1794-OF4IXT
FLEX I/O-XT isolated analog output module
1794-IN129
1794-UM008
1794-TB3
FLEX I/O terminal base unit
1794-TB3S
FLEX I/O terminal base unit
1794-TB3T
FLEX I/O temperature terminal base unit
1794-TB3TS
FLEX I/O spring-clamp temperature terminal base
unit
1794-TB3G
FLEX I/O cage-clamp generic terminal base unit
1794-TB3GS
FLEX I/O spring-clamp generic terminal base unit
1794-TBN
FLEX I/O NEMA terminal base unit
1794-TBNF
FLEX I/O NEMA fused terminal base unit
1794-IN050
1794-UM012
1794-IN049
1794-UM011
1794-IN092
(1) Some catalog numbers have a K suffix. This indicates a version of the product that has conformal coating. These K versions have the
same SIL 2 certification as the non-K versions. For more information on which products have conformal coating go to
http://ab.com.rockwellautomation.com/
(2) These publications are available from Rockwell Automation by visiting
http://www.rockwellautomation.com/literature.
116
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Appendix
C
PFD and PFH Calculations for a SIL 2 System
About PFD and PFH
Calculations
Topic
Page
About PFD and PFH Calculations
117
Determine Which Values To Use
118
About the Calculations in This Manual
118
1-Year PFD Calculations
119
2-Year PFD Calculations
124
5-year PFD Calculations
129
Using Component Values To Calculate System PFD
134
Probability of failure on demand (PFD) is the SIL value for a safety-related
system as related directly to order-of-magnitude ranges of its average probability
of failure to satisfactorily perform its safety function on demand. IEC 61508
quantifies this classification by stating that the frequency of demands for
operation of the safety system is no greater than once per year in the Low
Demand mode.
PFD calculations are commonly used for process safety applications and
applications where emergency stop devices (ESDs) are used.
Although PFD values are usually associated with each of the three elements
making up a safety-related system (the sensors, the actuators, and the logic
element), they can be associated with each component of the logic element, that
is, each module of a programmable controller.
Probability of failure per hour (PFH) is typically used to describe safety
performance for high demand applications. Because ControlLogix is suitable for
high demand applications up to and including 10 demands per year, PFH values
for those applications are provided.
Tables in this chapter present PFD and PFH values for ControlLogix and
ControlLogix-XT components that are evaluated by TÜV.
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
117
Appendix C
PFD and PFH Calculations for a SIL 2 System
Determine Which Values
To Use
IMPORTANT
You are responsible for determining which of the values provided are
appropriate for your SIL 2-certified system. Determine which values to use
based on the modules used your system and the system configuration.
Each of the PFD and PFH calculated values provided in this manual is based on
the configuration that the module can be used in, that is 1oo1 or 1oo2.
• Communication and controller communication modules have PFD values
specific to use in a 1oo1 configuration.
• Input or output modules have PFD values specific to use in a 1oo2
configuration.
About the Calculations in
This Manual
For the calculations presented in this chapter, these values were used as the two
application-dependent variables:
• Mean time to restoration (MTTR) is ten hours.
• Proof test interval (T1) is listed for each table.
Common Terms
λ = failure rate = 1/MTBF
λs = rate of safe failures = λ x 50%
λd = rate of dangerous failures = λ x 50%
λdd= dangerous, detected failure rate = λ/2 x DC
λdu= dangerous, undetected failure rate = λ/2 x (1-DC)
SFF = safe failure fraction =(λs +λdd)/λ
TCE1oo1 = channel equivalent down time = λdu/λd x (T1/2 + MRT) + (λd/λd x MTTR)
DC = diagnostic coverage
ß = common cause failure rate
ßd = common cause failure rate, dangerous
1oo1 Configuration
STR1oo1 = spurious trip rate = λs + λdd
PFD1oo1 = (λdd + λdu) x TCE
PFH1oo1 = λdu
1oo2 Configuration
STR1oo2 = spurious trip rate = 2 x (λs + λdd)
TGE1oo2 = system equivalent down time = λdu/ λd x (T1/3 + MRT) + (λdd/ λd x MTTR)
PFD1oo2= 2 x [(1-ßD) x λdd + (1-ß) x λdu]2 x TCE x TGE + (ßD x λdd x MTTR) + ß x λdu x (T1/2 + MRT)
PFH1oo2 = 2 x [(1-ßD) x λdd + (1-ß) x λdu] x (1-ß) x λdu x TCE + ß x λdu
The PFD and PFH values in this manual are calculated with formulas explained
in IEC 61508, Part 6, Annex B. Refer to IEC 61508, Part 6, for more
information about calculating PFD values for your system.
118
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
PFD and PFH Calculations for a SIL 2 System
1-Year PFD Calculations
Appendix C
The PFD calculations in this table are calculated for a 1-year proof test interval
(8760 hours) and are specific to ControlLogix system components.
Table 10 - 1- Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction λdu
(SFF)
1oo1 Configuration
λdd
TCE1oo1
Spurious
Trip Rate PFH(10)
STR
PFD
1756-AXX(2)
C
ControlLogix chassis
22,652,010 4.41E-08 2.21E-08 95%
2.21E-09 1.99E-08 448
4.19E-08
1756-A4LXT
B
4-slot ControlLogix-XT chassis
1,069,120
9.35E-07 4.68E-07 95%
4.68E-08 4.21E-07 448
8.89E-07
4.68E-08 2.10E-04
1756-A5XT
C
5-slot ControlLogix-XT chassis
734,420
1.36E-06 6.81E-07 95%
6.81E-08 6.13E-07 448
1.29E-06
6.81E-08 3.05E-04
1.81E-09 8.11E-06
B
7-slot ControlLogix-XT chassis
27,628,178 3.62E-08 1.81E-08 95%
1.81E-09 1.63E-08 448
3.44E-08
1756-A7XT
C
7-slot ControlLogix-XT chassis
1,081,600
9.25E-07 4.62E-07 95%
4.62E-08 4.16E-07 448
8.78E-07
4.62E-08 2.07E-04
1756-PB72
C
18-32V DC 10A ControlLogix
power supply
31,561,095 3.17E-08 1.58E-08 95%
1.58E-09 1.43E-08 448
3.01E-08
1.58E-09 7.10E-06
1756-PA72
C
85-265V AC 10A ControlLogix
power supply
18,336,146 5.45E-08 2.73E-08 95%
2.73E-09 2.45E-08 448
5.18E-08
2.73E-09 1.22E-05
1756-PA75
B
85-265V AC 13A ControlLogix
power supply (75W)
18,693,044 5.35E-08 2.67E-08 95%
2.67E-09 2.41E-08 448
5.08E-08
2.67E-09 1.20E-05
1756-PA75R
A
85-265V AC 13A Redundant
ControlLogix power supply
1,412,877
7.08E-07 3.54E-07 95%
3.54E-08 3.18E-07 448
6.72E-07
3.54E-08 1.59E-04
1756-PB75
B
18-32V DC 13A ControlLogix
power supply
15,675,475 6.38E-08 3.19E-08 95%
3.19E-09 2.87E-08 448
6.06E-08
3.19E-09 1.43E-05
1756-PB75R
A
18-32V DC 13A Redundant
ControlLogix power supply
1,736,020
2.88E-08 2.59E-07 448
5.47E-07
2.88E-08 1.29E-04
1756-PAXT
B
1756-PBXT
B
1756-PC75
ControlLogix-XT AC power supply 18,693,044 5.35E-08
Not
Applicable
2.67E-08 95%
2.67E-09 2.41E-08 448
5.08E-08
2.67E-09 1.20E-05
ControlLogix-XT DC power
supply
1,855,360
5.39E-07 2.69E-07 95%
2.69E-08 2.43E-07 448
5.12E-07
2.69E-08 1.21E-04
B
30-60V DC 13A ControlLogix
power supply
5,894,836
1.70E-07 8.48E-08 95%
8.48E-09 7.63E-08 448
1.61E-07
8.48E-09 3.80E-05
1756-PH75
B
90-143V DC 13A ControlLogix
power supply
2,119,520
4.72E-07 2.36E-07 95%
2.36E-08 2.12E-07 448
4.48E-07
2.36E-08 1.06E-04
1756-PSCA
A
Redundant power supply
adapter
45,146,727 2.21E-08 1.11E-08 95%
1.11E-09 9.97E-09 448
2.10E-08
1.11E-09 4.96E-06
1756-PSCA2
A
Redundant power supply
adapter
38,461,280 2.60E-08 1.30E-08 95%
1.30E-09 1.17E-08 448
2.47E-08
1.30E-09 5.82E-06
1786-RPFS
A
ControlNet Fiber repeater - short 26,461,760 3.78E-08 1.89E-08 95%
1.89E-09 1.70E-08 448
3.59E-08
1.89E-09 8.47E-06
1786-RPFM
A
ControlNet Fiber repeater medium
2.99E-09 2.69E-08 448
5.69E-08
2.99E-09 1.34E-05
1786-RPFRL
A
ControlNet Fiber repeater - long 5,717,227
1.75E-07 8.75E-08 95%
8.75E-09 7.87E-08 448
1.66E-07
8.75E-09 3.92E-05
1786-RPCD
A
ControlNet Hub repeater
28,654,080 3.49E-08 1.74E-08 95%
1.74E-09 1.57E-08 448
3.32E-08
1.74E-09 7.82E-06
16,697,862 5.99E-08 2.99E-08 95%
PFH(10)
PFD
2.21E-09 9.89E-06
1756-A7LXT
5.76E-07 2.88E-07 95%
1oo2 Configuration
Spurious
Trip Rate TGE
STR
1786-RPA
B
ControlNet repeater adapter
11,826,146 8.46E-08 4.23E-08 95%
4.23E-09 3.81E-08 448
8.03E-08
4.23E-09 1.89E-05
1786-RPFRXL
B
ControlNet Fiber repeater - extra 11,373,440 8.79E-08 4.40E-08 95%
long
4.40E-09 3.96E-08 448
8.35E-08
4.40E-09 1.97E-05
1756-L61(3)
B 20.012
ControlLogix controller, 2MB
1,000,053
1.00E-06 5.00E-07 95%
5.00E-08 4.50E-07 448
9.50E-07
5.00E-08 2.24E-04
ControlLogix controller, 4MB
1,034,830
9.66E-07 4.83E-07 95%
4.83E-08 4.35E-07 448
9.18E-07
4.83E-08 2.16E-04
ControlLogix controller, 8MB
1,055,910
9.47E-07 4.74E-07 95%
4.74E-08 4.26E-07 448
9.00E-07
4.74E-08 2.12E-04
ControlLogix-XT controller, 8MB 357,760
2.80E-06 1.40E-06 95%
1.40E-07 1.26E-06 448
2.66E-06
1.40E-07 6.26E-04
ControlLogix controller, 2MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 340
2.91E-06
1.01E-07 4.50E-04
ControlLogix controller, 4MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 340
2.91E-06
1.01E-07 4.50E-04
ControlLogix controller, 8MB
Calculated 2.69E-06 1.34E-06 96%
MTBF and
PFD via 2.69E-06 1.34E-06 96%
FMEA
1.01E-07 1.25E-06 340
2.91E-06
1.01E-07 4.50E-04
1.01E-07 1.25E-06 340
2.91E-06
1.01E-07 4.50E-04
ControlLogix controller, 16MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 340
2.91E-06
1.01E-07 4.50E-04
ControlLogix controller, 32MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 340
2.91E-06
1.01E-07 4.50E-04
Not Applicable
20.055
1756-L62(3)
B 20.012
20.055
1756-L63(3)
B 20.012
20.055
1756-L63XT(3)
B 20.012
20.055
(4)
1756-L71
B 20.012
20.055
(4)
1756-L72
B 20.012
Not Applicable
20.055
1756-L73(4)
B 20.012
20.055
1756-L73XT(4)
B 20.012
ControlLogix-XT controller, 8MB
20.055
1756-L74(4)
B 20.012
20.055
1756-L75(4)
B 20.012
20.055
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
119
Appendix C
PFD and PFH Calculations for a SIL 2 System
Table 10 - 1- Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction λdu
(SFF)
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
PFD
1756-CNB
E 11.005
ControlLogix ControlNet
communication module
1,786,977
5.60E-07 2.80E-07 95%
2.80E-08 2.52E-07 448
5.32E-07
2.80E-08 1.25E-04
1756-CNBR
E 11.005
ControlLogix ControlNet
redundant communication
module
2,608,543
3.83E-07 1.92E-07 95%
1.92E-08 1.73E-07 448
3.64E-07
1.92E-08 8.59E-05
1756-CN2
B 20.011
ControlLogix ControlNet
communication module
1,096,299
9.12E-07 4.56E-07 95%
4.56E-08 4.10E-07 448
8.67E-07
4.56E-08 2.04E-04
1756-CN2
C 25.004
ControlLogix ControlNet
communication module
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 303.63 1.91E-06
6.62E-08 3.0E-04
1756-CN2R
B 20.011
ControlLogix ControlNet
redundant communication
module
1,096,299
9.12E-07 4.56E-07 95%
4.56E-08 4.10E-07 448
4.56E-08 2.04E-04
1756-CN2R
C 25.004
ControlLogix ControlNet
redundant communication
module
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 303.63 1.91E-06
6.62E-08 3.0E-04
1756-CN2RXT
B 20.011
ControlLogix-XT ControlNet
redundant communication
module
1,980,160
5.05E-07 2.53E-07 95%
2.53E-08 2.27E-07 448
2.53E-08 1.13E-04
1756-CN2RXT
C 25.004
ControlLogix-XT ControlNet
redundant communication
module
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 303.63 1.91E-06
1756-DHRIO(5)
E 7.002
ControlLogix Data Highway Plus 2,503,396
Remote I/O Module
1756-DHRIOXT(5)
E 7.002
ControlLogix-XT Data Highway
Plus Remote I/O Module
2,503,396
8.67E-07
4.80E-07
D 12.005
ControlLogix DeviceNet
communication module
2,192,202
3.31E-07
1756-ENBT(5)
A 4.008
ControlLogix EtherNet/IP
communication module
2,088,198
3.47E-07
6.006
3.81E-08 3.43E-07 448
PFD
Not Applicable
5.79E-07
Not applicable
Not applicable
6.61E-07
6.94E-07
1756-EN2T
C 5.008
ControlLogix EtherNet/IP
communication module
1,312,712
1756-EN2T
D 10.007
ControlLogix EtherNet/IP
communication module
269,774
1756-EN2TR
B 5.008
ControlLogix EtherNet/IP
communication module with
fault tolerance
3,664,960
2.73E-07 1.36E-07 95%
1.36E-08 1.23E-07 448
1756-EN2TR
C 10.006
ControlLogix EtherNet/IP
communication module with
fault tolerance
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 303.63 1.91E-06
6.62E-08 3.0E-04
3.82E-06
258.2
1.36E-09 6.11E-06
1756-EN2TRXT
C 10.006
ControlLogix EtherNet/IP
communication module with
fault tolerance
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 303.63 1.91E-06
6.62E-08 3.0E-04
3.82E-06
258.2
1.36E-09 6.11E-06
1756-EN2TXT
C 5.008
ControlLogix-XT EtherNet/IP
communication module
1,300,000
7.69E-07 3.85E-07 95%
3.85E-08 3.46E-07 448
3.85E-08 1.72E-04 Not applicable
1756-EN2TXT
D 10.007
ControlLogix-XT EtherNet/IP
communication module
269,774
3.71E-06
1756-EN3TR
B 10.007
ControlLogix EtherNet/IP
communication module with
fault tolerance
269,774
3.71E-06
1756-RM(5)
B 3.003
ControlLogix redundancy
module
1,373,840
7.28E-07
1756-RM2
A 20.004
ControlLogix enhanced
redundancy module
250,182
1756-RM2XT
A 20.004
ControlLogix-XT enhanced
redundancy module
250,182
4.00E-06
1756-RMXT(5)
B 3.003
ControlLogix-XT redundancy
module
980,096
1.02E-06
1756-SYNCH(5)
A 2.018
ControlLogix SyncLink Module
6,932,640
1.05E-07
Not applicable
1756-IA16I
A 3.003
ControlLogix isolated V AC input 20,801,920 4.81E-08 2.40E-08 80%
module
9.61E-09 1.44E-08 1762
3.85E-08
9.61E-09 4.24E-05 7.69E-08
1178
4.81E-10 2.12E-06
1756-IA8D
A 3.003
ControlLogix diagnostic V AC
input module
15,966,080 6.26E-08 3.13E-08 80%
1.25E-08 1.88E-08 1762
5.01E-08
1.25E-08 5.52E-05 1.00E-07
1178
6.28E-10 2.76E-06
1756-IB16D
A 3.003
ControlLogix diagnostic V DC
input module
30,228,640 3.31E-08 1.65E-08 80%
6.62E-09 9.92E-09 1762
2.65E-08
6.62E-09 2.91E-05 5.29E-08
1178
3.31E-10 1.46E-06
1756-IB16I
A 3.003
ControlLogix isolated V DC input 81,443,094 1.23E-08 6.14E-09 80%
module
2.46E-09 3.68E-09 1762
9.82E-09
2.46E-09 1.08E-05 1.96E-08
1178
1.23E-10 5.41E-07
120
7.62E-07 3.81E-07 95%
PFH(10)
5.79E-07
2.90E-07
1756-DNB(5)
Spurious
Trip Rate TGE
STR
6.62E-08 3.0E-04
2.90E-07
Non-interference only
1oo2 Configuration
Non-interference only
7.24E-07
3.81E-08 1.71E-04
3.71E-06
Not applicable
2.59E-07
1.36E-08 6.11E-05
Not applicable
Non-interference only
7.31E-07
Not applicable
4.00E-06
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
2.09E-07
Not applicable
PFD and PFH Calculations for a SIL 2 System
Appendix C
Table 10 - 1- Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction λdu
(SFF)
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
Spurious
Trip Rate TGE
STR
1.73E-08 7.64E-05 1.39E-07
PFD
A 2.007
ControlLogix isolated V DC
Sequence Of Events input
module
11,537,760 8.67E-08 4.33E-08 80%
1.73E-08 2.60E-08 1762
1756-IB32
B 3.005
ControlLogix V DC input module 10,462,329 9.56E-08 4.78E-08 80%
1.91E-08 2.87E-08 1762
7.65E-08
1.91E-08 8.42E-05 1.53E-07
1178
9.59E-10 4.22E-06
1756-IF8
A 1.005
ControlLogix analog input
module
8,699,254
1.15E-07 5.75E-08 80%
2.30E-08 3.45E-08 1762
9.20E-08
2.30E-08 1.01E-04 1.84E-07
1178
1.15E-09 5.08E-06
1756-IF8H
A 1.002
ControlLogix HART analog input 1,291,978
module
7.74E-07 3.87E-07 80%
1.55E-07 2.32E-07 1762
6.19E-07
1.55E-07 6.82E-04 1.24E-06
1178
7.93E-09 3.47E-05
1756-IF16
A 1.005
ControlLogix analog input
module
2.18E-07 1.09E-07 80%
4.35E-08 6.53E-08 1762
1.74E-07
4.35E-08 1.92E-04 3.48E-07
1178
2.19E-09 9.64E-06
1756-IF16H
A 1.002
ControlLogix HART analog input 442,914
module
2.26E-06 1.13E-06 80%
4.52E-07 6.77E-07 1762
1.81E-06
4.52E-07 1.99E-03 3.61E-06
1178
2.42E-08 1.04E-04
1756-IF6CIS
A 1.013
ControlLogix isolated analog
input module
2,654,080
3.77E-07 1.88E-07 80%
7.54E-08 1.13E-07 1762
3.01E-07
7.54E-08 3.32E-04 6.03E-07
1178
3.81E-09 1.67E-05
1756-IF6I
A 1.013
ControlLogix isolated analog
input module
4,176,185
2.39E-07 1.20E-07 80%
4.79E-08 7.18E-08 1762
1.92E-07
4.79E-08 2.11E-04 3.83E-07
1178
2.41E-09 1.06E-05
1756-IH16ISOE
A 2.007
ControlLogix V DC Sequence Of
Events input module
2,150,720
4.65E-07 2.32E-07 80%
9.30E-08 1.39E-07 1762
3.72E-07
9.30E-08 4.10E-04 7.44E-07
1178
4.72E-09 2.07E-05
1756-IR6I
A 1.013
ControlLogix isolated RTD input
module
4,268,525
2.34E-07 1.17E-07 80%
4.69E-08 7.03E-08 1762
3.75E-07
1178
2.36E-09 1.04E-05
1756-IT6I
A 1.013
ControlLogix isolated
thermocouple input module
3,957,824
2.53E-07 1.26E-07 80%
5.05E-08 7.58E-08 1762
4.04E-07
1178
2.55E-09 1.12E-05
1756-IT6I2
A 1.013
ControlLogix isolated enhanced
thermocouple input module
2,720,046
3.68E-07 1.84E-07 80%
7.35E-08 1.10E-07 1762
5.88E-07
1178
3.72E-09 1.63E-05
1756-OA16I
A 3.002
ControlLogix V AC output
module
32,891,456 3.04E-08 1.52E-08 80%
6.08E-09 9.12E-09 1762
2.43E-08
6.08E-09 2.68E-05 4.86E-08
1178
3.04E-10 1.34E-06
1756-OA8D
A 3.003
ControlLogix V AC diagnostic
output module
11,311,040 8.84E-08 4.42E-08 80%
1.77E-08 2.65E-08 1762
7.07E-08
1.77E-08 7.79E-05 1.41E-07
1178
8.87E-10 3.90E-06
1756-OB16D
A 3.002
ControlLogix V DC diagnostic
output module
8,884,374
1.13E-07 5.63E-08 80%
2.25E-08 3.38E-08 1762
9.00E-08
2.25E-08 9.92E-05 1.80E-07
1178
1.13E-09 4.97E-06
1756-OB16E
A 3.003
ControlLogix V DC electronic ally- 14,997,714 6.67E-08 3.33E-08 80%
fused output module
1.33E-08 2.00E-08 1762
5.33E-08
1.33E-08 5.87E-05 1.07E-07
1178
6.68E-10 2.94E-06
1756-OB16I
A 3.002
ControlLogix V DC isolated
output module
7,388,160
1.35E-07 6.77E-08 80%
2.71E-08 4.06E-08 1762
1.08E-07
2.71E-08 1.19E-04 2.17E-07
1178
1.36E-09 5.98E-06
1756-OB32
A 3.002
ControlLogix V DC output
module
2,681,316
3.73E-07 1.86E-07 80%
7.46E-08 1.12E-07 1762
2.98E-07
7.46E-08 3.29E-04 5.97E-07
1178
3.77E-09 1.66E-05
1756-OB8EI
A 3.002
ControlLogix V DC isolated
electronic ally-fused output
module
14,019,200 7.13E-08 3.57E-08 80%
1.43E-08 2.14E-08 1762
5.71E-08
1.43E-08 6.28E-05 1.14E-07
1178
7.15E-10 3.15E-06
1756-OX8I
A 3.002
ControlLogix isolated relay
output module
6,059,635
1.65E-07 8.25E-08 80%
3.30E-08 4.95E-08 1762
1.32E-07
3.30E-08 1.45E-04 2.64E-07
1178
1.66E-09 7.29E-06
1756-OW16I
A 3.002
ControlLogix isolated relay
output module
13,695,899 7.30E-08 3.65E-08 80%
1.46E-08 2.19E-08 1762
5.84E-08
1.46E-08 6.43E-05 1.17E-07
1178
7.32E-10 3.22E-06
1756-OF8
A 1.005
ControlLogix analog output
module
10,629,795 9.41E-08 4.70E-08 80%
1.88E-08 2.82E-08 1762
7.53E-08
1.88E-08 8.29E-05 1.51E-07
1178
9.44E-10 4.15E-06
1756-OF6VI
A 1.013
ControlLogix isolated analog
output module
21,604,960 4.63E-08 2.31E-08 80%
9.26E-09 1.39E-08 1762
3.70E-08
9.26E-09 4.08E-05 7.41E-08
1178
4.64E-10 2.04E-06
1756-OF6CI
A 1.013
ControlLogix isolated analog
output module
8,354,667
1.20E-07 5.98E-08 80%
2.39E-08 3.59E-08 1762
9.58E-08
2.39E-08 1.05E-04 1.92E-07
1178
1.20E-09 5.29E-06
1756-OF8H
A 1.002
ControlLogix HART analog
output module
5,118,187
1.95E-07 9.77E-08 80%
3.91E-08 5.86E-08 1762
1.56E-07
3.91E-08 1.72E-04 3.13E-07
1178
1.97E-09 8.64E-06
Not allowed for 1oo1
configurations
1178
PFH(10)
1756-IB16ISOE
4,592,506
6.93E-08
PFD
1oo2 Configuration
8.69E-10 3.82E-06
1794-ACN15
D 10.003
FLEX I/O ControlNet adapter
8,223,684
1.22E-07 6.08E-08 80%
2.43E-08 3.65E-08 1762
1.95E-07
1178
1.22E-09 5.37E-06
1794-ACNR15
D 10.003
FLEX I/O ControlNet redundant
adapter
8,223,684
1.22E-07 6.08E-08 80%
2.43E-08 3.65E-08 1762
1.95E-07
1178
1.22E-09 5.37E-06
1794-ACNR15XT
D 10.003
FLEX I/O-XT ControlNet adapter
8,223,684
1.22E-07 6.08E-08 80%
2.43E-08 3.65E-08 1762
1794-AENT
B 4.003
FLEX I/O EtherNET/IP adapter
1,779,827
5.62E-07 2.81E-07 80%
1.12E-07 1.69E-07 1762
1794-AENTR
A 1.013
FLEX I/O EtherNET/IP adapter,
Ring media
1,268,070
7.89E-07 3.94E-07 80%
1794-AENTRXT
A 1.013
FLEX I/O EtherNET/IP adapter,
Ring media
1,268,070
7.89E-07 3.94E-07 80%
1.95E-07
1178
1.22E-09 5.37E-06
8.99E-07
1178
5.72E-09 2.50E-05
1.58E-07 2.37E-07 1762
1.26E-06
1178
8.08E-09 3.53E-05
1.58E-07 2.37E-07 1762
1.26E-06
1178
8.08E-09 3.53E-05
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Not allowed for 1oo1
configurations
121
Appendix C
PFD and PFH Calculations for a SIL 2 System
Table 10 - 1- Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
1794-IB16
A
1794-IB16XT
Not
A Applicable FLEX I/O-XT
FLEX I/O 24V DC input module
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction λdu
(SFF)
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
PFD
1oo2 Configuration
Spurious
Trip Rate TGE
STR
PFH(10)
PFD
179,506,15 5.57E-09 2.79E-09 80%
8
1.11E-09 1.67E-09 1762
8.91E-09
1178
5.57E-11 2.45E-07
35,587,189 2.81E-08 1.40E-08 80%
5.62E-09 8.43E-09 1762
4.50E-08
1178
2.81E-10 1.24E-06
24V DC input module
1794-IJ2
A D
FLEX I/O counter module
55,344,640 1.81E-08 9.03E-09 80%
3.61E-09 5.42E-09 1762
1794-IJ2XT
A E
FLEX I/O-XT counter module
11,714,128 8.54E-08 4.27E-08 80%
1.71E-08 2.56E-08 1762
1794-IP4
B 4
FLEX I/O counter module
22,027,200 4.54E-08 2.27E-08 80%
9.08E-09 1.36E-08 1762
7.26E-08
1178
4.55E-10 2.00E-06
1794-IB10XOB6
A
FLEX I/O 24V DC input/output
module
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 1762
1.60E-08
1178
1.00E-10 4.41E-07
1794IB10XOB6XT
A
FLEX I/O-XT
24V DC input/output module
22,202,487 4.50E-08 2.25E-08 80%
9.01E-09 1.35E-08 1762
7.21E-08
1178
4.51E-10 1.99E-06
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 1762
1.60E-08
1178
1.00E-10 4.41E-07
fused output module
14,771,049 6.77E-08 3.38E-08 80%
1.35E-08 2.03E-08 1762
1.08E-07
1178
6.78E-10 2.99E-06
2.95E-08
1178
1.84E-10 8.11E-07
1.60E-08
1178
1.00E-10 4.41E-07
1794-OB8EP
Not
A Applicable FLEX I/O 24V DC electronically-
FLEX I/O-XT 24V DC
electronically-fused output
module
Not allowed for 1oo1
configurations
2.89E-08
1178
1.81E-10 7.96E-07
1.37E-07
1178
8.56E-10 3.77E-06
1794-OB8EPXT
A
1794-OB16
A
FLEX I/O 24V DC output module 54,322,632 1.84E-08 9.20E-09 80%
3.68E-09 5.52E-09 1762
1794-OB16P
A
FLEX I/O 24V DC protected
output module
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 1762
1794-OB16PXT
A
FLEX I/O-XT
26,709,401 3.74E-08 1.87E-08 80%
7.49E-09 1.12E-08 1762
5.99E-08
1178
3.75E-10 1.65E-06
1794-OW8
A
FLEX I/O isolated relay output
module
29,088,895 3.44E-08 1.72E-08 80%
6.88E-09 1.03E-08 1762
5.50E-08
1178
3.44E-10 1.52E-06
1794-OW8XT
A
FLEX I/O-XT isolated relay output 18,518,519 5.40E-08 2.70E-08 80%
module
1.08E-08 1.62E-08 1762
8.64E-08
1178
5.41E-10 2.38E-06
FLEX I/O analog input module
Not
Applicable 24V DC protected output module
Not allowed for 1oo1
configurations
1794-IE8
B
18,914,770 5.29E-08 2.64E-08 80%
1.06E-08 1.59E-08 1762
8.46E-08
1178
5.30E-10 2.33E-06
1794-IE8XT
B Applicable FLEX I/O-XT analog input
module
14,041,000 7.12E-08 3.56E-08 80%
1.42E-08 2.14E-08 1762
1.14E-07
1178
7.14E-10 3.14E-06
1794-IF4I
A I
FLEX I/O isolated analog input
module
9,885,959
1.01E-07 5.06E-08 80%
2.02E-08 3.03E-08 1762
1.62E-07
1178
1.01E-09 4.47E-06
1794-IF4IXT
A I
FLEX I/O-XT isolated analog
input module
7,297,140
1.37E-07 6.85E-08 80%
2.74E-08 4.11E-08 1762
2.19E-07
1178
1.38E-09 6.05E-06
1794-IF4ICFXT
A I
FLEX I/O-XT isolated analog
input module
7,297,140
1.37E-07 6.85E-08 80%
2.74E-08 4.11E-08 1762
2.19E-07
1178
1.38E-09 6.05E-06
1794-IR8
A K
FLEX I/O RTD input module
5,016,231
1.99E-07 9.97E-08 80%
3.99E-08 5.98E-08 1762
3.19E-07
1178
2.01E-09 8.82E-06
1794-IR8XT
A K
FLEX I/O-XT RTD input module
9,585,890
1.04E-07 5.22E-08 80%
2.09E-08 3.13E-08 1762
1.67E-07
1178
1.05E-09 4.61E-06
1794-IRT8
B E.1
FLEX I/O RTD/Thermocouple
input module
1,407,269
7.11E-07 3.55E-07 80%
1.42E-07 2.13E-07 1762
1.14E-06
1178
7.27E-09 3.18E-05
1794-IRT8XT
B E.1
FLEX I/O-XT RTD/Thermocouple
input module
8,204,792
1.22E-07 6.09E-08 80%
2.44E-08 3.66E-08 1762
1.95E-07
1178
1.22E-09 5.38E-06
1794-IT8
A K
FLEX I/O Thermocouple input
module
2,097,509
4.77E-07 2.38E-07 80%
9.54E-08 1.43E-07 1762
7.63E-07
1178
4.84E-09 2.12E-05
1794-IF2XOF2I
A I
FLEX I/O isolated analog input/
output module
8,464,844
1.18E-07 5.91E-08 80%
2.36E-08 3.54E-08 1762
1.89E-07
1178
1.19E-09 5.22E-06
1794-IF2XOF2IXT A I
FLEX I/O-XT isolated analog
input/output module
6,317,918
1.58E-07 7.91E-08 80%
3.17E-08 4.75E-08 1762
2.53E-07
1178
1.59E-09 7.00E-06
1794-IE4XOE2XT B
FLEX I/O-XT analog input/output 11,800,802 8.47E-08 4.24E-08 80%
module
1.69E-08 2.54E-08 1762
1.36E-07
1178
8.50E-10 3.74E-06
Not
Not allowed for 1oo1
configurations
1794-OE4
B Not
Applicable FLEX I/O analog output module
18,433,610 5.42E-08 2.71E-08 80%
1.08E-08 1.63E-08 1762
8.68E-08
1178
5.43E-10 2.39E-06
1794-OE4XT
B
FLEX I/O-XT analog output
module
11,381,744 8.79E-08 4.39E-08 80%
1.76E-08 2.64E-08 1762
1.41E-07
1178
8.81E-10 3.88E-06
1794-OF4I
A I
FLEX I/O analog output module
23,884,409 4.19E-08 2.09E-08 80%
8.37E-09 1.26E-08 1762
6.70E-08
1178
4.19E-10 1.85E-06
1794-OF4IXT
A I
FLEX I/O-XT analog output
module
5,493,902
3.64E-08 5.46E-08 1762
2.91E-07
1178
1.83E-09 8.05E-06
122
1.82E-07 9.10E-08 80%
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Not allowed for 1oo1
configurations
PFD and PFH Calculations for a SIL 2 System
Appendix C
Table 10 - 1- Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction λdu
(SFF)
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
PFD
1oo2 Configuration
Spurious
Trip Rate TGE
STR
PFH(10)
PFD
1794-TB3
A
FLEX I/O terminal base unit
250,000,00 4.00E-09 2.00E-09 80%
0
8.00E-10 1.20E-09 1762
6.40E-09
1178
4.00E-11 1.76E-07
1794-TB3G
A
FLEX I/O cage-clamp generic
terminal base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 1762
1.60E-08
1178
1.00E-10 4.41E-07
1794-TB3GS
A
FLEX I/O spring-clamp generic
terminal base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 1762
1.60E-08
1178
1.00E-10 4.41E-07
1794-TB3S
A
FLEX I/O terminal base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 1762
1.60E-08
1178
1.00E-10 4.41E-07
1794-TB3T
Not
A Applicable FLEX I/O temperature terminal
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 1762
1.60E-08
1178
1.00E-10 4.41E-07
base unit
Not allowed for 1oo1
configurations
1794-TB3TS
A
FLEX I/O spring-clamp
temperature terminal base unit
52,312,000 1.91E-08 9.56E-09 80%
3.82E-09 5.73E-09 1762
3.06E-08
1178
1.91E-10 8.42E-07
1794-TBN
A
FLEX I/O NEMA terminal base
unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 1762
1.60E-08
1178
1.00E-10 4.41E-07
1794-TBNF
A
FLEX I/O NEMA fused terminal
base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 1762
1.60E-08
1178
1.00E-10 4.41E-07
1492-TIFM40FF24A-2(5)
A
DC Input Termination Board
7,779,000
Analog Input Termination Board 11,362,000
1492-TAIFM16-F- A Not
Applicable
3(5)
1492-TIFM4OF24-2(5)
A
DC Output Termination Board
10,127,000
1.03E-07
Non-interference only
7.04E-08
7.90E-08
7.90E-08
Not Applicable
1.03E-07
Not Applicable
7.04E-08
(1) Some catalog numbers have a K suffix. This indicates a version of the product that has conformal coating. These K versions have the same SIL 2 certification as the non-K versions. For more information on
which products have conformal coating go to http://ab.com.rockwellautomation.com/
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Average of 1756-A4, -A7, -A10, -A13 and -A17 chassis.
Suitable for use only in applications requiring compliance to IEC 61508 1999 Edition 1.
Calculated MTBF and PFD by FMEA to 61508-2010.
SIL 2-rated for non-interference in the chassis. Data not required within a safety function.
For the latest official approved firmware versions, consult the Revision Release List, Certificate Number 968/EZ/35.xx/xx available at
http://www.rockwellautomation.com/rockwellautomation/certification/safety.page.
MTBF measured in hours unless calculated (as noted). Field return values – January 2012.
Calculations performed on a per module basis.
λ = Failure Rate = 1/MTBF.
Demand rate must be less than 10 per year.
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
123
Appendix C
PFD and PFH Calculations for a SIL 2 System
2-Year PFD Calculations
The PFD calculations in this table are calculated for a 2-year proof test interval
(17,520 hours) and are specific to ControlLogix system components.
Table 11 - 2-Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction
(SFF)
λdu
1oo1 Configuration
λdd
TCE1oo1
Spurious
Trip Rate PFH(10)
STR
PFD
1756-AXX(2)
C
ControlLogix chassis
22,652,010 4.41E-08 2.21E-08 95%
2.21E-09 1.99E-08 886
4.19E-08
2.21E-09 1.96E-05
1756-A4LXT
B
4-slot ControlLogix-XT chassis
1,069,120
9.35E-07 4.68E-07 95%
4.68E-08 4.21E-07 886
8.89E-07
4.68E-08 4.14E-04
1756-A5XT
C
5-slot ControlLogix-XT chassis
734,420
1.36E-06 6.81E-07 95%
6.81E-08 6.13E-07 886
1.29E-06
6.81E-08 6.03E-04
1756-A7LXT
B
7-slot ControlLogix-XT chassis
27,628,178 3.62E-08 1.81E-08 95%
1.81E-09 1.63E-08 886
3.44E-08
1.81E-09 1.60E-05
1756-A7XT
C
7-slot ControlLogix-XT chassis
1,081,600
9.25E-07 4.62E-07 95%
4.62E-08 4.16E-07 886
8.78E-07
4.62E-08 4.10E-04
1756-PB72
C
18-32V DC 10A ControlLogix
power supply
31,561,095 3.17E-08 1.58E-08 95%
1.58E-09 1.43E-08 886
3.01E-08
1.58E-09 1.40E-05
1756-PA72
C
85-265V AC 10A ControlLogix
power supply
18,336,146 5.45E-08 2.73E-08 95%
2.73E-09 2.45E-08 886
5.18E-08
2.73E-09 2.42E-05
1756-PA75
B
85-265V AC 13A ControlLogix
power supply (75W)
18,693,044 5.35E-08 2.67E-08 95%
2.67E-09 2.41E-08 886
5.08E-08
2.67E-09 2.37E-05
1756-PA75R
A
85-265V AC 13A Redundant
ControlLogix power supply
1,412,877
7.08E-07 3.54E-07 95%
3.54E-08 3.18E-07 886
6.72E-07
3.54E-08 3.14E-04
1756-PB75
B
18-32V DC 13A ControlLogix
power supply
15,675,475 6.38E-08 3.19E-08 95%
3.19E-09 2.87E-08 886
6.06E-08
3.19E-09 2.83E-05
1756-PB75R
A
18-32V DC 13A Redundant
ControlLogix power supply
1,736,020
2.88E-08 2.59E-07 886
5.47E-07
2.88E-08 2.55E-04
1756-PAXT
B
1756-PBXT
B
1756-PC75
5.76E-07 2.88E-07 95%
ControlLogix-XT AC power supply 18,693,044 5.35E-08 2.67E-08 95%
Not
Applicable
2.67E-09 2.41E-08 886
5.08E-08
2.67E-09 2.37E-05
ControlLogix-XT DC power
supply
1,855,360
5.39E-07 2.69E-07 95%
2.69E-08 2.43E-07 886
5.12E-07
2.69E-08 2.39E-04
B
30-60V DC 13A ControlLogix
power supply
5,894,836
1.70E-07 8.48E-08 95%
8.48E-09 7.63E-08 886
1.61E-07
8.48E-09 7.52E-05
1756-PH75
B
90-143V DC 13A ControlLogix
power supply
2,119,520
4.72E-07 2.36E-07 95%
2.36E-08 2.12E-07 886
4.48E-07
2.36E-08 2.09E-04
1756-PSCA
A
Redundant power supply
adapter
45,146,727 2.21E-08 1.11E-08 95%
1.11E-09 9.97E-09 886
2.10E-08
1.11E-09 9.81E-06
1756-PSCA2
A
Redundant power supply
adapter
38,461,280 2.60E-08 1.30E-08 95%
1.30E-09 1.17E-08 886
2.47E-08
1.30E-09 1.15E-05
1786-RPFS
A
ControlNet Fiber repeater - short 26,461,760 3.78E-08 1.89E-08 95%
1.89E-09 1.70E-08 886
3.59E-08
1.89E-09 1.67E-05
1786-RPFM
A
ControlNet Fiber repeater medium
2.99E-09 2.69E-08 886
5.69E-08
2.99E-09 2.65E-05
1786-RPFRL
A
ControlNet Fiber repeater - long 5,717,227
1.75E-07 8.75E-08 95%
8.75E-09 7.87E-08 886
1.66E-07
8.75E-09 7.75E-05
1786-RPCD
A
ControlNet Hub repeater
28,654,080 3.49E-08 1.74E-08 95%
1.74E-09 1.57E-08 886
3.32E-08
1.74E-09 1.55E-05
1786-RPA
B
ControlNet repeater adapter
11,826,146 8.46E-08 4.23E-08 95%
4.23E-09 3.81E-08 886
8.03E-08
4.23E-09 3.75E-05
1786-RPFRXL
B
ControlNet Fiber repeater - extra 11,373,440 8.79E-08 4.40E-08 95%
long
4.40E-09 3.96E-08 886
8.35E-08
4.40E-09 3.90E-05
1756-L61(3)
B 20.012
ControlLogix controller, 2MB
1,000,053
1.00E-06 5.00E-07 95%
5.00E-08 4.50E-07 886
9.50E-07
5.00E-08 4.43E-04
ControlLogix controller, 4MB
1,034,830
9.66E-07 4.83E-07 95%
4.83E-08 4.35E-07 886
9.18E-07
4.83E-08 4.28E-04
ControlLogix controller, 8MB
1,055,910
9.47E-07 4.74E-07 95%
4.74E-08 4.26E-07 886
9.00E-07
4.74E-08 4.20E-04
ControlLogix-XT controller, 8MB 357,760
2.80E-06 1.40E-06 95%
1.40E-07 1.26E-06 886
2.66E-06
1.40E-07 1.24E-03
ControlLogix controller, 2MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 670
2.91E-06
1.01E-07 8.90E-04
ControlLogix controller, 4MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 670
2.91E-06
1.01E-07 8.90E-04
ControlLogix controller, 8MB
Calculated 2.69E-06 1.34E-06 96%
MTBF and
PFD via 2.69E-06 1.34E-06 96%
FMEA
1.01E-07 1.25E-06 670
2.91E-06
1.01E-07 8.90E-04
1.01E-07 1.25E-06 670
2.91E-06
1.01E-07 8.90E-04
ControlLogix controller, 16MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 670
2.91E-06
1.01E-07 8.90E-04
ControlLogix controller, 32MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 670
2.91E-06
1.01E-07 8.90E-04
16,697,862 5.99E-08 2.99E-08 95%
1oo2 Configuration
Spurious
Trip Rate TGE
STR
PFH(10)
Not Applicable
20.055
1756-L62(3)
B 20.012
20.055
1756-L63(3)
B 20.012
20.055
1756-L63XT(3)
B 20.012
20.055
(4)
1756-L71
B 20.012
20.055
1756-L72(4)
B 20.012
20.055
1756-L73(4)
B 20.012
20.055
1756-L73XT(4)
B 20.012
ControlLogix-XT controller, 8MB
20.055
1756-L74(4)
B 20.012
20.055
1756-L75(4)
B 20.012
20.055
124
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Not Applicable
PFD
PFD and PFH Calculations for a SIL 2 System
Appendix C
Table 11 - 2-Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction
(SFF)
λdu
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
PFD
1756-CNB
E 11.005
ControlLogix ControlNet
communication module
1,786,977
5.60E-07 2.80E-07 95%
2.80E-08 2.52E-07 886
5.32E-07
2.80E-08 2.48E-04
1756-CNBR
E 11.005
ControlLogix ControlNet
redundant communication
module
2,608,543
3.83E-07 1.92E-07 95%
1.92E-08 1.73E-07 886
3.64E-07
1.92E-08 1.70E-04
1756-CN2
B 20.011
ControlLogix ControlNet
communication module
1,096,299
9.12E-07 4.56E-07 95%
4.56E-08 4.10E-07 886
8.67E-07
4.56E-08 4.04E-04
1756-CN2
C 25.004
ControlLogix ControlNet
communication module
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 597.25
1.91E-06
6.62E-08 5.90E-04
1756-CN2R
B 20.011
ControlLogix ControlNet
redundant communication
module
1,096,299
9.12E-07 4.56E-07 95%
4.56E-08 4.10E-07 886
8.67E-07
4.56E-08 4.04E-04
1756-CN2R
C 25.004
ControlLogix ControlNet
redundant communication
module
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 597.25
1.91E-06
6.62E-08 5.90E-04
1756-CN2RXT
B 20.011
ControlLogix-XT ControlNet
redundant communication
module
1,980,160
5.05E-07 2.53E-07 95%
2.53E-08 2.27E-07 886
4.80E-07
2.53E-08 2.24E-04
1756-CN2RXT
C 25.004
ControlLogix-XT ControlNet
redundant communication
module
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 597.25
1.91E-06
6.62E-08 5.90E-04
1756-DHRIO(5)
E 7.002
ControlLogix Data Highway Plus 2,503,396
Remote I/O Module
1756-DHRIOXT(5)
E 7.002
ControlLogix-XT Data Highway
Plus Remote I/O Module
2,503,396
1756-DNB(5)
D 12.005
ControlLogix DeviceNet
communication module
2,192,202
1756-ENBT(5)
A 4.008
ControlLogix EtherNet/IP
communication module
2,088,198
6.006
3.79E-07
4.33E-07
3.81E-08 3.43E-07 886
PFH(10)
PFD
Not Applicable
7.59E-07
Not applicable
4.55E-07
7.62E-07 3.81E-07 95%
Spurious
Trip Rate TGE
STR
7.59E-07
3.79E-07
Non-interference only
1oo2 Configuration
Not applicable
8.67E-07
9.10E-07
1756-EN2T
C 5.008
ControlLogix EtherNet/IP
communication module
1,312,712
7.24E-07
3.81E-08 3.37E-04
1756-EN2T
D 10.007
ControlLogix EtherNet/IP
communication module
269,774
3.71E-06
Not applicable
1756-EN2TR
B 5.008
ControlLogix EtherNet/IP
communication module with
fault tolerance
3,664,960
2.73E-07 1.36E-07 95%
1.36E-08 1.23E-07 886
2.59E-07
1.36E-08 1.21E-04
1756-EN2TR
C 10.006
ControlLogix EtherNet/IP
communication module with
fault tolerance
1756-EN2TRXT
C 10.006
ControlLogix EtherNet/IP
communication module with
fault tolerance
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 597.25
1.91E-06
6.62E-08 5.90E-04 3.82E-06
401.50 1.40E-09 1.22E-05
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 597.25
1.91E-06
6.62E-08 5.90E-04 3.82E-06
401.50 1.40E-09 1.22E-05
1756-EN2TXT
C 5.008
ControlLogix-XT EtherNet/IP
communication module
1,300,000
7.69E-07 3.85E-07 95%
3.85E-08 3.46E-07 886
7.31E-07
3.85E-08 3.41E-04
1756-EN2TXT
D 10.007
ControlLogix-XT EtherNet/IP
communication module
269,774
3.71E-06
1756-EN3TR
B 10.007
ControlLogix EtherNet/IP
communication module with
fault tolerance
269,774
3.71E-06
1756-RM(5)
B 3.003
ControlLogix redundancy
module
1,373,840
6.91E-07
1756-RM2
A 20.004
ControlLogix enhanced
redundancy module
250,182
1756-RM2XT
A 20.004
ControlLogix-XT enhanced
redundancy module
250,182
4.00E-06
1756-RMXT(5)
B 3.003
ControlLogix-XT redundancy
module
980,096
9.69E-07
1756-SYNCH(5)
A 2.018
ControlLogix SyncLink Module
6,932,640
1.37E-07
Not applicable
1756-IA16I
A 3.003
ControlLogix isolated V AC input 20,801,920 4.81E-08 2.40E-08 80%
module
9.61E-09 1.44E-08 3514
3.85E-08
9.61E-09 8.45E-05 7.69E-08
2346
4.82E-10 4.23E-06
1756-IA8D
A 3.003
ControlLogix diagnostic V AC
input module
15,966,080 6.26E-08 3.13E-08 80%
1.25E-08 1.88E-08 3514
5.01E-08
1.25E-08 1.10E-04 1.00E-07
2346
6.29E-10 5.52E-06
1756-IB16D
A 3.003
ControlLogix diagnostic V DC
input module
30,228,640 3.31E-08 1.65E-08 80%
6.62E-09 9.92E-09 3514
2.65E-08
6.62E-09 5.81E-05 5.29E-08
2346
3.32E-10 2.91E-06
1756-IB16I
A 3.003
ControlLogix isolated V DC input 81,443,094 1.23E-08 6.14E-09 80%
module
2.46E-09 3.68E-09 3514
9.82E-09
2.46E-09 2.16E-05 1.96E-08
2346
1.23E-10 1.08E-06
Non-interference only
Not Applicable
Non-interference only
Not Applicable
Not applicable
4.00E-06
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
2.74E-07
Not applicable
125
Appendix C
PFD and PFH Calculations for a SIL 2 System
Table 11 - 2-Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction
(SFF)
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
6.93E-08
Spurious
Trip Rate TGE
STR
1.73E-08 1.52E-04 1.39E-07
PFD
ControlLogix isolated V DC
Sequence Of Events input
module
1756-IB32
B 3.005
ControlLogix V DC input module 10,462,329 9.56E-08 4.78E-08 80%
1.91E-08 2.87E-08 3514
7.65E-08
1.91E-08 1.68E-04 1.53E-07
2346
9.62E-10 8.43E-06
1756-IF8
A 1.005
ControlLogix analog input
module
8,699,254
1.15E-07 5.75E-08 80%
2.30E-08 3.45E-08 3514
9.20E-08
2.30E-08 2.02E-04 1.84E-07
2346
1.16E-09 1.01E-05
1756-IF8H
A 1.002
ControlLogix HART analog input 1,291,978
module
7.74E-07 3.87E-07 80%
1.55E-07 2.32E-07 3514
6.19E-07
1.55E-07 1.36E-03 1.24E-06
2346
8.12E-09 7.02E-05
1756-IF16
A 1.005
ControlLogix analog input
module
2.18E-07 1.09E-07 80%
4.35E-08 6.53E-08 3514
1.74E-07
4.35E-08 3.83E-04 3.48E-07
2346
2.21E-09 1.93E-05
1756-IF16H
A 1.002
ControlLogix HART analog input 442,914
module
2.26E-06 1.13E-06 80%
4.52E-07 6.77E-07 3514
1.81E-06
4.52E-07 3.97E-03 3.61E-06
2346
2.58E-08 2.17E-04
1756-IF6CIS
A 1.013
ControlLogix isolated analog
input module
2,654,080
3.77E-07 1.88E-07 80%
7.54E-08 1.13E-07 3514
3.01E-07
7.54E-08 6.62E-04 6.03E-07
2346
3.86E-09 3.36E-05
1756-IF6I
A 1.013
ControlLogix isolated analog
input module
4,176,185
2.39E-07 1.20E-07 80%
4.79E-08 7.18E-08 3514
1.92E-07
4.79E-08 4.21E-04 3.83E-07
2346
2.43E-09 2.12E-05
1756-IH16ISOE
A 2.007
ControlLogix V DC Sequence Of
Events input module
2,150,720
4.65E-07 2.32E-07 80%
9.30E-08 1.39E-07 3514
3.72E-07
9.30E-08 8.17E-04 7.44E-07
2346
4.79E-09 4.17E-05
1756-IR6I
A 1.013
ControlLogix isolated RTD input
module
4,268,525
2.34E-07 1.17E-07 80%
4.69E-08 7.03E-08 3514
3.75E-07
2346
2.38E-09 2.08E-05
1756-IT6I
A 1.013
ControlLogix isolated
thermocouple input module
3,957,824
2.53E-07 1.26E-07 80%
5.05E-08 7.58E-08 3514
4.04E-07
2346
2.57E-09 2.24E-05
1756-IT6I2
A 1.013
ControlLogix isolated enhanced
thermocouple input module
2,720,046
3.68E-07 1.84E-07 80%
7.35E-08 1.10E-07 3514
5.88E-07
2346
3.76E-09 3.28E-05
1756-OA16I
A 3.002
ControlLogix V AC output
module
32,891,456 3.04E-08 1.52E-08 80%
6.08E-09 9.12E-09 3514
2.43E-08
6.08E-09 5.34E-05 4.86E-08
2346
3.05E-10 2.67E-06
1756-OA8D
A 3.003
ControlLogix V AC diagnostic
output module
11,311,040 8.84E-08 4.42E-08 80%
1.77E-08 2.65E-08 3514
7.07E-08
1.77E-08 1.55E-04 1.41E-07
2346
8.89E-10 7.80E-06
1756-OB16D
A 3.002
ControlLogix V DC diagnostic
output module
8,884,374
1.13E-07 5.63E-08 80%
2.25E-08 3.38E-08 3514
9.00E-08
2.25E-08 1.98E-04 1.80E-07
2346
1.13E-09 9.94E-06
1756-OB16E
A 3.003
ControlLogix V DC electronic ally- 14,997,714 6.67E-08 3.33E-08 80%
fused output module
1.33E-08 2.00E-08 3514
5.33E-08
1.33E-08 1.17E-04 1.07E-07
2346
6.70E-10 5.87E-06
1756-OB16I
A 3.002
ControlLogix V DC isolated
output module
7,388,160
1.35E-07 6.77E-08 80%
2.71E-08 4.06E-08 3514
1.08E-07
2.71E-08 2.38E-04 2.17E-07
2346
1.37E-09 1.20E-05
1756-OB32
A 3.002
ControlLogix V DC output
module
2,681,316
3.73E-07 1.86E-07 80%
7.46E-08 1.12E-07 3514
2.98E-07
7.46E-08 6.55E-04 5.97E-07
2346
3.82E-09 3.33E-05
1756-OB8EI
A 3.002
ControlLogix V DC isolated
electronic ally-fused output
module
14,019,200 7.13E-08 3.57E-08 80%
1.43E-08 2.14E-08 3514
5.71E-08
1.43E-08 1.25E-04 1.14E-07
2346
7.17E-10 6.29E-06
1756-OX8I
A 3.002
ControlLogix isolated relay
output module
6,059,635
1.65E-07 8.25E-08 80%
3.30E-08 4.95E-08 3514
1.32E-07
3.30E-08 2.90E-04 2.64E-07
2346
1.67E-09 1.46E-05
1756-OW16I
A 3.002
ControlLogix isolated relay
output module
13,695,899 7.30E-08 3.65E-08 80%
1.46E-08 2.19E-08 3514
5.84E-08
1.46E-08 1.28E-04 1.17E-07
2346
7.34E-10 6.43E-06
1756-OF8
A 1.005
ControlLogix analog output
module
10,629,795 9.41E-08 4.70E-08 80%
1.88E-08 2.82E-08 3514
7.53E-08
1.88E-08 1.65E-04 1.51E-07
2346
9.46E-10 8.30E-06
1756-OF6VI
A 1.013
ControlLogix isolated analog
output module
21,604,960 4.63E-08 2.31E-08 80%
9.26E-09 1.39E-08 3514
3.70E-08
9.26E-09 8.13E-05 7.41E-08
2346
4.64E-10 4.07E-06
1756-OF6CI
A 1.013
ControlLogix isolated analog
output module
8,354,667
1.20E-07 5.98E-08 80%
2.39E-08 3.59E-08 3514
9.58E-08
2.39E-08 2.10E-04 1.92E-07
2346
1.21E-09 1.06E-05
1756-OF8H
A 1.002
ControlLogix HART analog
output module
5,118,187
1.95E-07 9.77E-08 80%
3.91E-08 5.86E-08 3514
1.56E-07
3.91E-08 3.43E-04 3.13E-07
2346
1.98E-09 1.73E-05
1794-ACN15
D 10.003
FLEX I/O ControlNet adapter
8,223,684
1.22E-07 6.08E-08 80%
2.43E-08 3.65E-08 3514
1.95E-07
2346
1.23E-09 1.07E-05
1794-ACNR15
D 10.003
FLEX I/O ControlNet redundant
adapter
8,223,684
1.22E-07 6.08E-08 80%
2.43E-08 3.65E-08 3514
1.95E-07
2346
1.23E-09 1.07E-05
1794-ACNR15XT
D 10.003
FLEX I/O-XT ControlNet adapter
8,223,684
1.22E-07 6.08E-08 80%
2.43E-08 3.65E-08 3514
1794-AENT
B 4.003
FLEX I/O EtherNET/IP adapter
1,779,827
5.62E-07 2.81E-07 80%
1.12E-07 1.69E-07 3514
1794-AENTR
A 1.013
FLEX I/O EtherNET/IP adapter,
Ring media
1,268,070
7.89E-07 3.94E-07 80%
1794-AENTRXT
A 1.013
FLEX I/O EtherNET/IP adapter,
Ring media
1,268,070
7.89E-07 3.94E-07 80%
Not allowed for 1oo1
configurations
2346
PFH(10)
A 2.007
4,592,506
1.73E-08 2.60E-08 3514
PFD
1oo2 Configuration
1756-IB16ISOE
126
11,537,760 8.67E-08 4.33E-08 80%
λdu
1oo1 Configuration
8.71E-10 7.64E-06
1.95E-07
2346
1.23E-09 1.07E-05
8.99E-07
2346
5.82E-09 5.05E-05
1.58E-07 2.37E-07 3514
1.26E-06
2346
8.28E-09 7.16E-05
1.58E-07 2.37E-07 3514
1.26E-06
2346
8.28E-09 7.16E-05
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Not allowed for 1oo1
configurations
PFD and PFH Calculations for a SIL 2 System
Appendix C
Table 11 - 2-Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
1794-IB16
A
1794-IB16XT
Not
A Applicable FLEX I/O-XT
FLEX I/O 24V DC input module
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction
(SFF)
λdu
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
PFD
1oo2 Configuration
Spurious
Trip Rate TGE
STR
PFH(10)
PFD
179,506,15 5.57E-09 2.79E-09 80%
8
1.11E-09 1.67E-09 3514
8.91E-09
2346
5.57E-11 4.90E-07
35,587,189 2.81E-08 1.40E-08 80%
5.62E-09 8.43E-09 3514
4.50E-08
2346
2.82E-10 2.47E-06
2.89E-08
2346
1.81E-10 1.59E-06
1.37E-07
2346
8.58E-10 7.53E-06
24V DC input module
1794-IJ2
A D
FLEX I/O counter module
55,344,640 1.81E-08 9.03E-09 80%
3.61E-09 5.42E-09 3514
1794-IJ2XT
A E
FLEX I/O-XT counter module
11,714,128 8.54E-08 4.27E-08 80%
1.71E-08 2.56E-08 3514
1794-IP4
B 4
FLEX I/O counter module
22,027,200 4.54E-08 2.27E-08 80%
9.08E-09 1.36E-08 3514
7.26E-08
2346
4.55E-10 4.00E-06
1794-IB10XOB6
A
FLEX I/O 24V DC input/output
module
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 3514
1.60E-08
2346
1.00E-10 8.79E-07
1794IB10XOB6XT
A
FLEX I/O-XT
24V DC input/output module
22,202,487 4.50E-08 2.25E-08 80%
9.01E-09 1.35E-08 3514
7.21E-08
2346
4.52E-10 3.96E-06
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 3514
1.60E-08
2346
1.00E-10 8.79E-07
fused output module
14,771,049 6.77E-08 3.38E-08 80%
1.35E-08 2.03E-08 3514
1.08E-07
2346
6.80E-10 5.96E-06
2.95E-08
2346
1.84E-10 1.62E-06
1.60E-08
2346
1.00E-10 8.79E-07
1794-OB8EP
Not
A Applicable FLEX I/O 24V DC electronically-
FLEX I/O-XT 24V DC
electronically-fused output
module
Not allowed for 1oo1
configurations
1794-OB8EPXT
A
1794-OB16
A
FLEX I/O 24V DC output module 54,322,632 1.84E-08 9.20E-09 80%
3.68E-09 5.52E-09 3514
1794-OB16P
A
FLEX I/O 24V DC protected
output module
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 3514
1794-OB16PXT
A
FLEX I/O-XT
26,709,401 3.74E-08 1.87E-08 80%
7.49E-09 1.12E-08 3514
5.99E-08
2346
3.75E-10 3.29E-06
1794-OW8
A
FLEX I/O isolated relay output
module
29,088,895 3.44E-08 1.72E-08 80%
6.88E-09 1.03E-08 3514
5.50E-08
2346
3.45E-10 3.02E-06
1794-OW8XT
A
FLEX I/O-XT isolated relay output 18,518,519 5.40E-08 2.70E-08 80%
module
1.08E-08 1.62E-08 3514
8.64E-08
2346
5.42E-10 4.75E-06
1794-IE8
B
FLEX I/O analog input module
18,914,770 5.29E-08 2.64E-08 80%
1.06E-08 1.59E-08 3514
8.46E-08
2346
5.30E-10 4.65E-06
1794-IE8XT
B Applicable FLEX I/O-XT analog input
module
14,041,000 7.12E-08 3.56E-08 80%
1.42E-08 2.14E-08 3514
1.14E-07
2346
7.15E-10 6.28E-06
1794-IF4I
A I
FLEX I/O isolated analog input
module
9,885,959
1.01E-07 5.06E-08 80%
2.02E-08 3.03E-08 3514
1.62E-07
2346
1.02E-09 8.92E-06
1794-IF4IXT
A I
FLEX I/O-XT isolated analog
input module
7,297,140
1.37E-07 6.85E-08 80%
2.74E-08 4.11E-08 3514
2.19E-07
2346
1.38E-09 1.21E-05
1794-IF4ICFXT
A I
FLEX I/O-XT isolated analog
input module
7,297,140
1.37E-07 6.85E-08 80%
2.74E-08 4.11E-08 3514
2.19E-07
2346
1.38E-09 1.21E-05
1794-IR8
A K
FLEX I/O RTD input module
5,016,231
1.99E-07 9.97E-08 80%
3.99E-08 5.98E-08 3514
3.19E-07
2346
2.02E-09 1.77E-05
1794-IR8XT
A K
FLEX I/O-XT RTD input module
9,585,890
1.04E-07 5.22E-08 80%
2.09E-08 3.13E-08 3514
1.67E-07
2346
1.05E-09 9.20E-06
1794-IRT8
B E.1
FLEX I/O RTD/Thermocouple
input module
1,407,269
7.11E-07 3.55E-07 80%
1.42E-07 2.13E-07 3514
1.14E-06
2346
7.43E-09 6.43E-05
1794-IRT8XT
B E.1
FLEX I/O-XT RTD/Thermocouple
input module
8,204,792
1.22E-07 6.09E-08 80%
2.44E-08 3.66E-08 3514
1.95E-07
2346
1.23E-09 1.08E-05
1794-IT8
A K
FLEX I/O Thermocouple input
module
2,097,509
4.77E-07 2.38E-07 80%
9.54E-08 1.43E-07 3514
7.63E-07
2346
4.91E-09 4.27E-05
1794-IF2XOF2I
A I
FLEX I/O isolated analog input/
output module
8,464,844
1.18E-07 5.91E-08 80%
2.36E-08 3.54E-08 3514
1.89E-07
2346
1.19E-09 1.04E-05
1794-IF2XOF2IXT A I
FLEX I/O-XT isolated analog
input/output module
6,317,918
1.58E-07 7.91E-08 80%
3.17E-08 4.75E-08 3514
2.53E-07
2346
1.60E-09 1.40E-05
1794-IE4XOE2XT B
FLEX I/O-XT analog input/output 11,800,802 8.47E-08 4.24E-08 80%
module
1.69E-08 2.54E-08 3514
1.36E-07
2346
8.52E-10 7.47E-06
Not
Applicable 24V DC protected output module
Not
Not allowed for 1oo1
configurations
Not allowed for 1oo1
configurations
1794-OE4
B Not
Applicable FLEX I/O analog output module
18,433,610 5.42E-08 2.71E-08 80%
1.08E-08 1.63E-08 3514
8.68E-08
2346
5.44E-10 4.78E-06
1794-OE4XT
B
FLEX I/O-XT analog output
module
11,381,744 8.79E-08 4.39E-08 80%
1.76E-08 2.64E-08 3514
1.41E-07
2346
8.83E-10 7.75E-06
1794-OF4I
A I
FLEX I/O analog output module
23,884,409 4.19E-08 2.09E-08 80%
8.37E-09 1.26E-08 3514
6.70E-08
2346
4.20E-10 3.68E-06
1794-OF4IXT
A I
FLEX I/O-XT analog output
module
5,493,902
3.64E-08 5.46E-08 3514
2.91E-07
2346
1.84E-09 1.61E-05
1.82E-07 9.10E-08 80%
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Not allowed for 1oo1
configurations
127
Appendix C
PFD and PFH Calculations for a SIL 2 System
Table 11 - 2-Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction
(SFF)
λdu
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
PFD
1oo2 Configuration
Spurious
Trip Rate TGE
STR
PFH(10)
PFD
1794-TB3
A
FLEX I/O terminal base unit
250,000,00 4.00E-09 2.00E-09 80%
0
8.00E-10 1.20E-09 3514
6.40E-09
2346
4.00E-11 3.51E-07
1794-TB3G
A
FLEX I/O cage-clamp generic
terminal base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 3514
1.60E-08
2346
1.00E-10 8.79E-07
1794-TB3GS
A
FLEX I/O spring-clamp generic
terminal base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 3514
1.60E-08
2346
1.00E-10 8.79E-07
1794-TB3S
A
FLEX I/O terminal base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 3514
1.60E-08
2346
1.00E-10 8.79E-07
1794-TB3T
Not
A Applicable FLEX I/O temperature terminal
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 3514
1.60E-08
2346
1.00E-10 8.79E-07
base unit
Not allowed for 1oo1
configurations
1794-TB3TS
A
FLEX I/O spring-clamp
temperature terminal base unit
52,312,000 1.91E-08 9.56E-09 80%
3.82E-09 5.73E-09 3514
3.06E-08
2346
1.91E-10 1.68E-06
1794-TBN
A
FLEX I/O NEMA terminal base
unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 3514
1.60E-08
2346
1.00E-10 8.79E-07
1794-TBNF
A
FLEX I/O NEMA fused terminal
base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 3514
1.60E-08
2346
1.00E-10 8.79E-07
1492-TIFM40FF24A-2(5)
A
DC Input Termination Board
7,779,000
Analog Input Termination Board 11,362,000
1492-TAIFM16-F- A Not
Applicable
3(5)
1492-TIFM4OF24-2(5)
A
DC Output Termination Board
10,127,000
1.03E-07
Non-interference only
7.04E-08
7.90E-08
1.03E-07
Not Applicable
7.04E-08
Not Applicable
7.90E-08
(1) Some catalog numbers have a K suffix. This indicates a version of the product that has conformal coating. These K versions have the same SIL 2 certification as the non-K versions. For more information on
which products have conformal coating go to http://ab.com.rockwellautomation.com/
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
128
Average of 1756-A4, -A7, -A10, -A13 and -A17 chassis.
Suitable for use only in applications requiring compliance to IEC 61508 1999 Edition 1
Calculated MTBF and PFD by FMEA to 61508-2010.
SIL 2-rated for non-interference in the chassis. Data not required within a safety function.
For the latest official approved firmware versions, consult the Revision Release List, Certificate Number 968/EZ/35.xx/xx available at
http://www.rockwellautomation.com/rockwellautomation/certification/safety.page.
MTBF measured in hours unless calculated (as noted). Field return values – January 2012.
Calculations performed on a per module basis.
λ = Failure Rate = 1/MTBF.
Demand rate must be less than 10 per year
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
PFD and PFH Calculations for a SIL 2 System
5-year PFD Calculations
Appendix C
The PFD calculations in this table are calculated for a 5-year proof test interval
(43,800 hours) and are specific to ControlLogix system components.
Table 12 - 5-Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction
(SFF)
λdu
1oo1 Configuration
λdd
TCE1oo1
Spurious
Trip Rate PFH(10)
STR
PFD
1756-AXX(2)
C
ControlLogix chassis
22,652,010 4.41E-08 2.21E-08 95%
2.21E-09 1.99E-08 2200
4.19E-08
1756-A4LXT
B
4-slot ControlLogix-XT chassis
1,069,120
9.35E-07 4.68E-07 95%
4.68E-08 4.21E-07 2200
8.89E-07
4.68E-08 1.03E-03
1756-A5XT
C
5-slot ControlLogix-XT chassis
734,420
1.36E-06 6.81E-07 95%
6.81E-08 6.13E-07 2200
1.29E-06
6.81E-08 1.50E-03
1756-A7LXT
B
7-slot ControlLogix-XT chassis
27,628,178 3.62E-08 1.81E-08 95%
1.81E-09 1.63E-08 2200
3.44E-08
1.81E-09 3.98E-05
1756-A7XT
C
7-slot ControlLogix-XT chassis
1,081,600
9.25E-07 4.62E-07 95%
4.62E-08 4.16E-07 2200
8.78E-07
4.62E-08 1.02E-03
1756-PB72
C
18-32V DC 10A ControlLogix
power supply
31,561,095 3.17E-08 1.58E-08 95%
1.58E-09 1.43E-08 2200
3.01E-08
1.58E-09 3.49E-05
1756-PA72
C
85-265V AC 10A ControlLogix
power supply
18,336,146 5.45E-08 2.73E-08 95%
2.73E-09 2.45E-08 2200
5.18E-08
2.73E-09 6.00E-05
1756-PA75
B
85-265V AC 13A ControlLogix
power supply (75W)
18,693,044 5.35E-08 2.67E-08 95%
2.67E-09 2.41E-08 2200
5.08E-08
2.67E-09 5.88E-05
1756-PA75R
A
85-265V AC 13A Redundant
ControlLogix power supply
1,412,877
7.08E-07 3.54E-07 95%
3.54E-08 3.18E-07 2200
6.72E-07
3.54E-08 7.79E-04
1756-PB75
B
18-32V DC 13A ControlLogix
power supply
15,675,475 6.38E-08 3.19E-08 95%
3.19E-09 2.87E-08 2200
6.06E-08
3.19E-09 7.02E-05
1756-PB75R
A
18-32V DC 13A Redundant
ControlLogix power supply
1,736,020
2.88E-08 2.59E-07 2200
5.47E-07
2.88E-08 6.34E-04
1756-PAXT
B
1756-PBXT
B
1756-PC75
5.76E-07 2.88E-07 95%
ControlLogix-XT AC power supply 18,693,044 5.35E-08 2.67E-08 95%
Not
Applicable
PFH(10) PFD
2.21E-09 4.86E-05
2.67E-09 2.41E-08 2200
5.08E-08
2.67E-09 5.88E-05
ControlLogix-XT DC power
supply
1,855,360
5.39E-07 2.69E-07 95%
2.69E-08 2.43E-07 2200
5.12E-07
2.69E-08 5.93E-04
B
30-60V DC 13A ControlLogix
power supply
5,894,836
1.70E-07 8.48E-08 95%
8.48E-09 7.63E-08 2200
1.61E-07
8.48E-09 1.87E-04
1756-PH75
B
90-143V DC 13A ControlLogix
power supply
2,119,520
4.72E-07 2.36E-07 95%
2.36E-08 2.12E-07 2200
4.48E-07
2.36E-08 5.19E-04
1756-PSCA
A
Redundant power supply
adapter
45,146,727 2.21E-08 1.11E-08 95%
1.11E-09 9.97E-09 2200
2.10E-08
1.11E-09 2.44E-05
1756-PSCA2
A
Redundant power supply
adapter
38,461,280 2.60E-08 1.30E-08 95%
1.30E-09 1.17E-08 2200
2.47E-08
1.30E-09 2.86E-05
1786-RPFS
A
ControlNet Fiber repeater - short 26,461,760 3.78E-08 1.89E-08 95%
1.89E-09 1.70E-08 2200
3.59E-08
1.89E-09 4.16E-05
1786-RPFM
A
ControlNet Fiber repeater medium
2.99E-09 2.69E-08 2200
5.69E-08
2.99E-09 6.59E-05
1786-RPFRL
A
ControlNet Fiber repeater - long 5,717,227
1.75E-07 8.75E-08 95%
8.75E-09 7.87E-08 2200
1.66E-07
8.75E-09 1.92E-04
1786-RPCD
A
ControlNet Hub repeater
28,654,080 3.49E-08 1.74E-08 95%
1.74E-09 1.57E-08 2200
3.32E-08
1.74E-09 3.84E-05
1786-RPA
B
ControlNet repeater adapter
11,826,146 8.46E-08 4.23E-08 95%
4.23E-09 3.81E-08 2200
8.03E-08
4.23E-09 9.30E-05
1786-RPFRXL
B
ControlNet Fiber repeater - extra 11,373,440 8.79E-08 4.40E-08 95%
long
4.40E-09 3.96E-08 2200
8.35E-08
4.40E-09 9.67E-05
1756-L61(3)
B 20.012
ControlLogix controller, 2MB
1,000,053
1.00E-06 5.00E-07 95%
5.00E-08 4.50E-07 2200
9.50E-07
5.00E-08 1.10E-03
ControlLogix controller, 4MB
1,034,830
9.66E-07 4.83E-07 95%
4.83E-08 4.35E-07 2200
9.18E-07
4.83E-08 1.06E-03
ControlLogix controller, 8MB
1,055,910
9.47E-07 4.74E-07 95%
4.74E-08 4.26E-07 2200
9.00E-07
4.74E-08 1.04E-03
ControlLogix-XT controller, 8MB 357,760
2.80E-06 1.40E-06 95%
1.40E-07 1.26E-06 2200
2.66E-06
1.40E-07 3.07E-03
ControlLogix controller, 2MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 1661
2.91E-06
1.01E-07 2.20E-03
ControlLogix controller, 4MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 1661
2.91E-06
1.01E-07 2.20E-03
ControlLogix controller, 8MB
Calculated 2.69E-06 1.34E-06 96%
MTBF and
PFD via 2.69E-06 1.34E-06 96%
FMEA
1.01E-07 1.25E-06 1661
2.91E-06
1.01E-07 2.20E-03
1.01E-07 1.25E-06 1661
2.91E-06
1.01E-07 2.20E-03
ControlLogix controller, 16MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 1661
2.91E-06
1.01E-07 2.20E-03
ControlLogix controller, 32MB
2.69E-06 1.34E-06 96%
1.01E-07 1.25E-06 1661
2.91E-06
1.01E-07 2.20E-03
16,697,862 5.99E-08 2.99E-08 95%
1oo2 Configuration
Spurious
Trip Rate TGE
STR
Not Applicable
20.055
1756-L62(3)
B 20.012
20.055
1756-L63(3)
B 20.012
20.055
(3)
1756-L63XT
B 20.012
20.055
(4)
1756-L71
B 20.012
20.055
1756-L72(4)
B 20.012
Not Applicable
20.055
1756-L73(4)
B 20.012
20.055
1756-L73XT(4)
B 20.012
ControlLogix-XT controller, 8MB
20.055
1756-L74(4)
B 20.012
20.055
(4)
1756-L75
B 20.012
20.055
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
129
Appendix C
PFD and PFH Calculations for a SIL 2 System
Table 12 - 5-Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction
(SFF)
λdu
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
PFD
1756-CNB
E 11.005
ControlLogix ControlNet
communication module
1,786,977
5.60E-07 2.80E-07 95%
2.80E-08 2.52E-07 2200
5.32E-07
2.80E-08 6.16E-04
1756-CNBR
E 11.005
ControlLogix ControlNet
redundant communication
module
2,608,543
3.83E-07 1.92E-07 95%
1.92E-08 1.73E-07 2200
3.64E-07
1.92E-08 4.22E-04
1756-CN2
B 20.011
ControlLogix ControlNet
communication module
1,096,299
9.12E-07 4.56E-07 95%
4.56E-08 4.10E-07 2200
8.67E-07
4.56E-08 1.00E-03
1756-CN2
C 25.004
ControlLogix ControlNet
communication module
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 1478.14 1.91E-06
6.62E-08 1.50E-03
1756-CN2R
B 20.011
ControlLogix ControlNet
redundant communication
module
1,096,299
9.12E-07 4.56E-07 95%
4.56E-08 4.10E-07 2200
8.67E-07
4.56E-08 1.00E-03
1756-CN2R
C 25.004
ControlLogix ControlNet
redundant communication
module
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 1478.14 1.91E-06
6.62E-08 1.50E-03
1756-CN2RXT
B 20.011
ControlLogix-XT ControlNet
redundant communication
module
1,980,160
5.05E-07 2.53E-07 95%
2.53E-08 2.27E-07 2200
4.80E-07
2.53E-08 5.56E-04
1756-CN2RXT
C 25.004
ControlLogix-XT ControlNet
redundant communication
module
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 1478.14 1.91E-06
6.62E-08 1.50E-03
E 7.002
ControlLogix Data Highway Plus 2,503,396
Remote I/O Module
E 7.002
ControlLogix-XT Data Highway
Plus Remote I/O Module
2,503,396
1756-DHRIO(5)
1756-DHRIOXT
(5)
1756-DNB(5)
D 12.005
ControlLogix DeviceNet
communication module
2,192,202
1756-ENBT(5)
A 4.008
ControlLogix EtherNet/IP
communication module
2,088,198
6.006
Non-interference only
7.62E-07 3.81E-07 95%
3.81E-08 3.43E-07 2200
3.79E-07
2.00E-08
3.79E-07
2.00E-08
1oo2 Configuration
Spurious
Trip Rate TGE
STR
PFH(10) PFD
Not Applicable
7.59E-07
4.33E-07
7.59E-07
Not
2.28E-08 applicable 8.67E-07
4.55E-07
2.39E-08
7.24E-07
3.81E-08 8.38E-04
3.71E-06
Not applicable
Not applicable
9.10E-07
1756-EN2T
C 5.008
ControlLogix EtherNet/IP
communication module
1,312,712
1756-EN2T
D 10.007
ControlLogix EtherNet/IP
communication module
269,774
1756-EN2TR
B 5.008
ControlLogix EtherNet/IP
communication module with
fault tolerance
3,664,960
2.73E-07 1.36E-07 95%
1.36E-08 1.23E-07 2200
2.59E-07
1.36E-08 3.00E-04
1756-EN2TR
C 10.006
ControlLogix EtherNet/IP
communication module with
fault tolerance
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 1478.14 1.91E-06
6.62E-08 1.50E-03
3.82E-06
988.76
1.51E-09 3.19E-05
1756-EN2TRXT
C 10.006
ControlLogix EtherNet/IP
communication module with
fault tolerance
Calculated
MTBF and
PFD via
FMEA
1.97E-06 9.87E-07 96.6%
6.62E-08 9.21E-07 1478.14 1.91E-06
6.62E-08 1.50E-03
3.82E-06
988.76
1.51E-09 3.19E-05
1756-EN2TXT
C 5.008
ControlLogix-XT EtherNet/IP
communication module
1,300,000
7.69E-07 3.85E-07 95%
3.85E-08 3.46E-07 2200
3.85E-08 8.46E-04
1756-EN2TXT
D 10.007
ControlLogix-XT EtherNet/IP
communication module
269,774
3.71E-06
1756-EN3TR
B 10.007
ControlLogix EtherNet/IP
communication module with
fault tolerance
269,774
3.71E-06
1756-RM(5)
B 3.003
ControlLogix redundancy
module
1,373,840
Non-interference only
Not Applicable
7.31E-07
6.91E-07
Non-interference only
Not Applicable
Not applicable
1756-RM2
A 20.004
ControlLogix enhanced
redundancy module
250,182
1756-RM2XT
A 20.004
ControlLogix-XT enhanced
redundancy module
250,182
4.00E-06
1756-RMXT(5)
B 3.003
ControlLogix-XT redundancy
module
980,096
9.69E-07
1756-SYNCH(5)
A 2.018
ControlLogix SyncLink Module
6,932,640
1.37E-07
Not applicable
2.74E-07
Not applicable
1756-IA16I
A 3.003
ControlLogix isolated V AC input 20,801,920 4.81E-08 2.40E-08 80%
module
9.61E-09 1.44E-08 8770
3.85E-08
9.61E-09 2.11E-04
7.69E-08
5850
4.84E-10 1.06E-05
1756-IA8D
A 3.003
ControlLogix diagnostic V AC
input module
15,966,080 6.26E-08 3.13E-08 80%
1.25E-08 1.88E-08 8770
5.01E-08
1.25E-08 2.75E-04
1.00E-07
5850
6.33E-10 1.38E-05
1756-IB16D
A 3.003
ControlLogix diagnostic V DC
input module
30,228,640 3.31E-08 1.65E-08 80%
6.62E-09 9.92E-09 8770
2.65E-08
6.62E-09 1.45E-04
5.29E-08
5850
3.33E-10 7.28E-06
1756-IB16I
A 3.003
ControlLogix isolated V DC input 81,443,094 1.23E-08 6.14E-09 80%
module
2.46E-09 3.68E-09 8770
9.82E-09
2.46E-09 5.38E-05
1.96E-08
5850
1.23E-10 2.70E-06
130
4.00E-06
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
PFD and PFH Calculations for a SIL 2 System
Appendix C
Table 12 - 5-Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction
(SFF)
λdu
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
1.73E-08 3.80E-04
Spurious
Trip Rate TGE
STR
PFH(10) PFD
1.39E-07
8.79E-10 1.92E-05
1756-IB16ISOE
A 2.007
ControlLogix isolated V DC
Sequence Of Events input
module
11,537,760 8.67E-08 4.33E-08 80%
1.73E-08 2.60E-08 8770
1756-IB32
B 3.005
ControlLogix V DC input module 10,462,329 9.56E-08 4.78E-08 80%
1.91E-08 2.87E-08 8770
7.65E-08
1.91E-08 4.19E-04
1.53E-07
5850
9.70E-10 2.12E-05
1756-IF8
A 1.005
ControlLogix analog input
module
8,699,254
1.15E-07 5.75E-08 80%
2.30E-08 3.45E-08 8770
9.20E-08
2.30E-08 5.04E-04
1.84E-07
5850
1.17E-09 2.55E-05
1756-IF8H
A 1.002
ControlLogix HART analog input 1,291,978
module
7.74E-07 3.87E-07 80%
1.55E-07 2.32E-07 8770
6.19E-07
1.55E-07 3.39E-03
1.24E-06
5850
8.69E-09 1.84E-04
1756-IF16
A 1.005
ControlLogix analog input
module
2.18E-07 1.09E-07 80%
4.35E-08 6.53E-08 8770
1.74E-07
4.35E-08 9.55E-04
3.48E-07
5850
2.25E-09 4.88E-05
1756-IF16H
A 1.002
ControlLogix HART analog input 442,914
module
2.26E-06 1.13E-06 80%
4.52E-07 6.77E-07 8770
1.81E-06
4.52E-07 9.90E-03
3.61E-06
5850
3.06E-08 6.13E-04
1756-IF6CIS
A 1.013
ControlLogix isolated analog
input module
2,654,080
3.77E-07 1.88E-07 80%
7.54E-08 1.13E-07 8770
3.01E-07
7.54E-08 1.65E-03
6.03E-07
5850
3.99E-09 8.59E-05
1756-IF6I
A 1.013
ControlLogix isolated analog
input module
4,176,185
2.39E-07 1.20E-07 80%
4.79E-08 7.18E-08 8770
1.92E-07
4.79E-08 1.05E-03
3.83E-07
5850
2.49E-09 5.38E-05
1756-IH16ISOE
A 2.007
ControlLogix
V DC Sequence Of Events input
module
2,150,720
4.65E-07 2.32E-07 80%
9.30E-08 1.39E-07 8770
3.72E-07
9.30E-08 2.04E-03
7.44E-07
5850
4.99E-09 1.07E-04
1756-IR6I
A 1.013
ControlLogix isolated RTD input
module
4,268,525
2.34E-07 1.17E-07 80%
4.69E-08 7.03E-08 8770
3.75E-07
5850
2.43E-09 5.26E-05
1756-IT6I
A 1.013
ControlLogix isolated
thermocouple input module
3,957,824
2.53E-07 1.26E-07 80%
5.05E-08 7.58E-08 8770
4.04E-07
5850
2.63E-09 5.69E-05
1756-IT6I2
A 1.013
ControlLogix isolated enhanced
thermocouple input module
2,720,046
3.68E-07 1.84E-07 80%
7.35E-08 1.10E-07 8770
5.88E-07
5850
3.89E-09 8.37E-05
1756-OA16I
A 3.002
ControlLogix V AC output
module
32,891,456 3.04E-08 1.52E-08 80%
6.08E-09 9.12E-09 8770
2.43E-08
6.08E-09 1.33E-04
4.86E-08
5850
3.05E-10 6.69E-06
1756-OA8D
A 3.003
ControlLogix V AC diagnostic
output module
11,311,040 8.84E-08 4.42E-08 80%
1.77E-08 2.65E-08 8770
7.07E-08
1.77E-08 3.88E-04
1.41E-07
5850
8.96E-10 1.96E-05
1756-OB16D
A 3.002
ControlLogix V DC diagnostic
output module
8,884,374
1.13E-07 5.63E-08 80%
2.25E-08 3.38E-08 8770
9.00E-08
2.25E-08 4.94E-04
1.80E-07
5850
1.15E-09 2.50E-05
1756-OB16E
A 3.003
ControlLogix V DC electronic ally- 14,997,714 6.67E-08 3.33E-08 80%
fused output module
1.33E-08 2.00E-08 8770
5.33E-08
1.33E-08 2.92E-04
1.07E-07
5850
6.74E-10 1.47E-05
1756-OB16I
A 3.002
ControlLogix V DC isolated
output module
7,388,160
1.35E-07 6.77E-08 80%
2.71E-08 4.06E-08 8770
1.08E-07
2.71E-08 5.94E-04
2.17E-07
5850
1.38E-09 3.01E-05
1756-OB32
A 3.002
ControlLogix V DC output
module
2,681,316
3.73E-07 1.86E-07 80%
7.46E-08 1.12E-07 8770
2.98E-07
7.46E-08 1.64E-03
5.97E-07
5850
3.95E-09 8.50E-05
1756-OB8EI
A 3.002
ControlLogix V DC isolated
electronic ally-fused output
module
14,019,200 7.13E-08 3.57E-08 80%
1.43E-08 2.14E-08 8770
5.71E-08
1.43E-08 3.13E-04
1.14E-07
5850
7.21E-10 1.58E-05
1756-OX8I
A 3.002
ControlLogix isolated relay
output module
6,059,635
1.65E-07 8.25E-08 80%
3.30E-08 4.95E-08 8770
1.32E-07
3.30E-08 7.24E-04
2.64E-07
5850
1.69E-09 3.68E-05
1756-OW16I
A 3.002
ControlLogix isolated relay
output module
13,695,899 7.30E-08 3.65E-08 80%
1.46E-08 2.19E-08 8770
5.84E-08
1.46E-08 3.20E-04
1.17E-07
5850
7.39E-10 1.61E-05
1756-OF8
A 1.005
ControlLogix analog output
module
10,629,795 9.41E-08 4.70E-08 80%
1.88E-08 2.82E-08 8770
7.53E-08
1.88E-08 4.13E-04
1.51E-07
5850
9.55E-10 2.08E-05
1756-OF6VI
A 1.013
ControlLogix isolated analog
output module
21,604,960 4.63E-08 2.31E-08 80%
9.26E-09 1.39E-08 8770
3.70E-08
9.26E-09 2.03E-04
7.41E-08
5850
4.66E-10 1.02E-05
1756-OF6CI
A 1.013
ControlLogix isolated analog
output module
8,354,667
1.20E-07 5.98E-08 80%
2.39E-08 3.59E-08 8770
9.58E-08
2.39E-08 5.25E-04
1.92E-07
5850
1.22E-09 2.66E-05
1756-OF8H
A 1.002
ControlLogix HART analog
output module
5,118,187
1.95E-07 9.77E-08 80%
3.91E-08 5.86E-08 8770
1.56E-07
3.91E-08 8.57E-04
3.13E-07
5850
2.01E-09 4.37E-05
4,592,506
6.93E-08
PFD
1oo2 Configuration
Not allowed for 1oo1
configurations
5850
1794-ACN15
D 10.003
FLEX I/O ControlNet adapter
8,223,684
1.22E-07 6.08E-08 80%
2.43E-08 3.65E-08 8770
1.95E-07
5850
1.24E-09 2.70E-05
1794-ACNR15
D 10.003
FLEX I/O ControlNet redundant
adapter
8,223,684
1.22E-07 6.08E-08 80%
2.43E-08 3.65E-08 8770
1.95E-07
5850
1.24E-09 2.70E-05
1794-ACNR15XT
D 10.003
FLEX I/O-XT ControlNet adapter
8,223,684
1.22E-07 6.08E-08 80%
2.43E-08 3.65E-08 8770
1794-AENT
B 4.003
FLEX I/O EtherNET/IP adapter
1,779,827
5.62E-07 2.81E-07 80%
1.12E-07 1.69E-07 8770
1794-AENTR
A 1.013
FLEX I/O EtherNET/IP adapter,
Ring media
1,268,070
7.89E-07 3.94E-07 80%
1794-AENTRXT
A 1.013
FLEX I/O EtherNET/IP adapter,
Ring media
1,268,070
7.89E-07 3.94E-07 80%
1.95E-07
5850
1.24E-09 2.70E-05
8.99E-07
5850
6.12E-09 1.30E-04
1.58E-07 2.37E-07 8770
1.26E-06
5850
8.87E-09 1.87E-04
1.58E-07 2.37E-07 8770
1.26E-06
5850
8.87E-09 1.87E-04
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Not allowed for 1oo1
configurations
131
Appendix C
PFD and PFH Calculations for a SIL 2 System
Table 12 - 5-Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
1794-IB16
A
1794-IB16XT
Not
A Applicable FLEX I/O-XT
FLEX I/O 24V DC input module
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction
(SFF)
λdu
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
PFD
1oo2 Configuration
Spurious
Trip Rate TGE
STR
PFH(10) PFD
179,506,15 5.57E-09 2.79E-09 80%
8
1.11E-09 1.67E-09 8770
8.91E-09
5850
5.58E-11 1.22E-06
35,587,189 2.81E-08 1.40E-08 80%
5.62E-09 8.43E-09 8770
4.50E-08
5850
2.82E-10 6.18E-06
2.89E-08
5850
1.81E-10 3.97E-06
1.37E-07
5850
8.65E-10 1.89E-05
24V DC input module
1794-IJ2
A D
FLEX I/O counter module
55,344,640 1.81E-08 9.03E-09 80%
3.61E-09 5.42E-09 8770
1794-IJ2XT
A E
FLEX I/O-XT counter module
11,714,128 8.54E-08 4.27E-08 80%
1.71E-08 2.56E-08 8770
1794-IP4
B 4
FLEX I/O counter module
22,027,200 4.54E-08 2.27E-08 80%
9.08E-09 1.36E-08 8770
7.26E-08
5850
4.57E-10 1.00E-05
1794-IB10XOB6
A
FLEX I/O 24V DC input/output
module
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 8770
1.60E-08
5850
1.00E-10 2.19E-06
1794IB10XOB6XT
A
FLEX I/O-XT
24V DC input/output module
22,202,487 4.50E-08 2.25E-08 80%
9.01E-09 1.35E-08 8770
7.21E-08
5850
4.54E-10 9.92E-06
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 8770
1.60E-08
5850
1.00E-10 2.19E-06
fused output module
14,771,049 6.77E-08 3.38E-08 80%
1.35E-08 2.03E-08 8770
1.08E-07
5850
6.84E-10 1.49E-05
2.95E-08
5850
1.85E-10 4.04E-06
1.60E-08
5850
1.00E-10 2.19E-06
1794-OB8EP
Not
A Applicable FLEX I/O 24V DC electronically-
FLEX I/O-XT 24V DC
electronically-fused output
module
Not allowed for 1oo1
configurations
1794-OB8EPXT
A
1794-OB16
A
FLEX I/O 24V DC output module 54,322,632 1.84E-08 9.20E-09 80%
3.68E-09 5.52E-09 8770
1794-OB16P
A
FLEX I/O 24V DC protected
output module
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 8770
1794-OB16PXT
A
FLEX I/O-XT
26,709,401 3.74E-08 1.87E-08 80%
7.49E-09 1.12E-08 8770
5.99E-08
5850
3.77E-10 8.24E-06
1794-OW8
A
FLEX I/O isolated relay output
module
29,088,895 3.44E-08 1.72E-08 80%
6.88E-09 1.03E-08 8770
5.50E-08
5850
3.46E-10 7.56E-06
1794-OW8XT
A
FLEX I/O-XT isolated relay output 18,518,519 5.40E-08 2.70E-08 80%
module
1.08E-08 1.62E-08 8770
8.64E-08
5850
5.45E-10 1.19E-05
FLEX I/O analog input module
Not
Applicable 24V DC protected output module
Not allowed for 1oo1
configurations
1794-IE8
B
18,914,770 5.29E-08 2.64E-08 80%
1.06E-08 1.59E-08 8770
8.46E-08
5850
5.33E-10 1.17E-05
1794-IE8XT
B Applicable FLEX I/O-XT analog input
module
14,041,000 7.12E-08 3.56E-08 80%
1.42E-08 2.14E-08 8770
1.14E-07
5850
7.20E-10 1.57E-05
1794-IF4I
A I
FLEX I/O isolated analog input
module
9,885,959
1.01E-07 5.06E-08 80%
2.02E-08 3.03E-08 8770
1.62E-07
5850
1.03E-09 2.24E-05
1794-IF4IXT
A I
FLEX I/O-XT isolated analog
input module
7,297,140
1.37E-07 6.85E-08 80%
2.74E-08 4.11E-08 8770
2.19E-07
5850
1.40E-09 3.05E-05
1794-IF4ICFXT
A I
FLEX I/O-XT isolated analog
input module
7,297,140
1.37E-07 6.85E-08 80%
2.74E-08 4.11E-08 8770
2.19E-07
5850
1.40E-09 3.05E-05
1794-IR8
A K
FLEX I/O RTD input module
5,016,231
1.99E-07 9.97E-08 80%
3.99E-08 5.98E-08 8770
3.19E-07
5850
2.06E-09 4.46E-05
1794-IR8XT
A K
FLEX I/O-XT RTD input module
9,585,890
1.04E-07 5.22E-08 80%
2.09E-08 3.13E-08 8770
1.67E-07
5850
1.06E-09 2.31E-05
1794-IRT8
B E.1
FLEX I/O RTD/Thermocouple
input module
1,407,269
7.11E-07 3.55E-07 80%
1.42E-07 2.13E-07 8770
1.14E-06
5850
7.91E-09 1.67E-04
1794-IRT8XT
B E.1
FLEX I/O-XT RTD/Thermocouple
input module
8,204,792
1.22E-07 6.09E-08 80%
2.44E-08 3.66E-08 8770
1.95E-07
5850
1.24E-09 2.71E-05
1794-IT8
A K
FLEX I/O Thermocouple input
module
2,097,509
4.77E-07 2.38E-07 80%
9.54E-08 1.43E-07 8770
7.63E-07
5850
5.13E-09 1.10E-04
1794-IF2XOF2I
A I
FLEX I/O isolated analog input/
output module
8,464,844
1.18E-07 5.91E-08 80%
2.36E-08 3.54E-08 8770
1.89E-07
5850
1.20E-09 2.62E-05
1794-IF2XOF2IXT A I
FLEX I/O-XT isolated analog
input/output module
6,317,918
1.58E-07 7.91E-08 80%
3.17E-08 4.75E-08 8770
2.53E-07
5850
1.62E-09 3.53E-05
1794-IE4XOE2XT B
FLEX I/O-XT analog input/output 11,800,802 8.47E-08 4.24E-08 80%
module
1.69E-08 2.54E-08 8770
1.36E-07
5850
8.59E-10 1.87E-05
Not
Not allowed for 1oo1
configurations
1794-OE4
B Not
Applicable FLEX I/O analog output module
18,433,610 5.42E-08 2.71E-08 80%
1.08E-08 1.63E-08 8770
8.68E-08
5850
5.47E-10 1.20E-05
1794-OE4XT
B
FLEX I/O-XT analog output
module
11,381,744 8.79E-08 4.39E-08 80%
1.76E-08 2.64E-08 8770
1.41E-07
5850
8.91E-10 1.94E-05
1794-OF4I
A I
FLEX I/O analog output module
23,884,409 4.19E-08 2.09E-08 80%
8.37E-09 1.26E-08 8770
6.70E-08
5850
4.21E-10 9.22E-06
1794-OF4IXT
A I
FLEX I/O-XT analog output
module
5,493,902
3.64E-08 5.46E-08 8770
2.91E-07
5850
1.87E-09 4.07E-05
132
1.82E-07 9.10E-08 80%
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Not allowed for 1oo1
configurations
PFD and PFH Calculations for a SIL 2 System
Appendix C
Table 12 - 5-Year PFD Calculations
Series
Cat No.(1)
Firmware
Version(6) Description
Mean Time
between
Failure
λ(9)
(MTBF)(7)
Common Terms(8)
λs , λd
Safe
Failure
Fraction
(SFF)
λdu
1oo1 Configuration
λdd
Spurious
TCE1oo1 Trip Rate PFH(10)
STR
PFD
1oo2 Configuration
Spurious
Trip Rate TGE
STR
PFH(10) PFD
1794-TB3
A
FLEX I/O terminal base unit
250,000,00 4.00E-09 2.00E-09 80%
0
8.00E-10 1.20E-09 8770
6.40E-09
5850
4.00E-11 8.77E-07
1794-TB3G
A
FLEX I/O cage-clamp generic
terminal base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 8770
1.60E-08
5850
1.00E-10 2.19E-06
1794-TB3GS
A
FLEX I/O spring-clamp generic
terminal base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 8770
1.60E-08
5850
1.00E-10 2.19E-06
1794-TB3S
A
FLEX I/O terminal base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 8770
1.60E-08
5850
1.00E-10 2.19E-06
1794-TB3T
Not
A Applicable FLEX I/O temperature terminal
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 8770
1.60E-08
5850
1.00E-10 2.19E-06
base unit
Not allowed for 1oo1
configurations
1794-TB3TS
A
FLEX I/O spring-clamp
temperature terminal base unit
52,312,000 1.91E-08 9.56E-09 80%
3.82E-09 5.73E-09 8770
3.06E-08
5850
1.92E-10 4.20E-06
1794-TBN
A
FLEX I/O NEMA terminal base
unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 8770
1.60E-08
5850
1.00E-10 2.19E-06
1794-TBNF
A
FLEX I/O NEMA fused terminal
base unit
100,000,00 1.00E-08 5.00E-09 80%
0
2.00E-09 3.00E-09 8770
1.60E-08
5850
1.00E-10 2.19E-06
1492-TIFM40FF24A-2(5)
A
DC Input Termination Board
7,779,000
Analog Input Termination Board 11,362,000
1492-TAIFM16-F- A Not
Applicable
3(5)
1492-TIFM4OF24-2(5)
A
DC Output Termination Board
10,127,000
7.04E-08
Non-interference only
7.90E-08
0.00E+00
1.03E-07
Not Applicable
7.04E-08
Not Applicable
0.00E+00
(1) Some catalog numbers have a K suffix. This indicates a version of the product that has conformal coating. These K versions have the same SIL 2 certification as the non-K versions. For more information on
which products have conformal coating go to http://ab.com.rockwellautomation.com/
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Average of 1756-A4, -A7, -A10, -A13 and -A17 chassis.
Suitable for use only in applications requiring compliance to IEC 61508 1999 Edition 1
Calculated MTBF and PFD by FMEA to 61508-2010.
SIL 2-rated for non-interference in the chassis. Data not required within a safety function.
For the latest official approved firmware versions, consult the Revision Release List, Certificate Number 968/EZ/35.xx/xx available at
http://www.rockwellautomation.com/rockwellautomation/certification/safety.page.
MTBF measured in hours unless calculated (as noted). Field return values – January 2012.
Calculations performed on a per module basis.
λ = Failure Rate = 1/MTBF.
Demand rate must be less than 10 per year
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
133
Appendix C
PFD and PFH Calculations for a SIL 2 System
Using Component Values To
Calculate System PFD
The system PFD value is calculated by totaling the PFD value of each component
in the system. To calculate a system PFD value, use this equation:
• modA PFD + modB PFD + modC PFD = system PFD
where modX PFD is the PFD value for one component or module in the system.
When calculating your system PFD, verify that all the components used in the
system are totaled.
Example: 1-year PFD Calculation for a ControlLogix System (1oo1
Configuration)
This example shows an example of a PFD calculation for a traditional
ControlLogix system in a fail-safe configuration. This example system uses one
chassis for the controller and a second chassis for the I/O.
Table 13 - Example of PFD Calculations for a Fail-safe System (1oo1 Configuration)
Cat. No.
Description
Calculated
1756-IB16D
ControlLogix V DC diagnostic input module
1.46E-06 (1oo2)
1756-EN2TR
Series C
ControlLogix EtherNet/IP communication module - I/O chassis
3.00E-04 (1oo1)
1756-L72
ControlLogix controller, 4 MB
4.50E-04 (1oo1)
1756-EN2TR
Series C
ControlLogix EtherNet/IP communication module - controller chassis
3.00E-04 (1oo1)
1756-OB16D
ControlLogix V DC diagnostic output module
4.97E-06 (1oo2)
Total safety loop PFD:
1.056E-03
Percent of SIL 2 budget:
10.56%
Example: 1-year PFD Calculation for a ControlLogix System (1oo2
Configuration)
See Figure 6 on page 20 for a system diagram of the example calculation shown
below.
134
Cat. No.
Description
Calculated
1756-IB16D
ControlLogix V DC diagnostic input module
1.46E-06 (1oo2)
1756-EN2TR
Series C
ControlLogix EtherNet/IP communication module - I/O chassis
6.11E-06 (1oo2)
1756-L72
ControlLogix controller, 4 MB
4.50E-04 (1oo1)
1756-EN2TR
Series C
ControlLogix EtherNet/IP communication module - controller chassis
6.11E-06 (1oo2)
1756-OB16D
ControlLogix V DC diagnostic output module
4.97E-06 (1oo2)
Total safety loop PFD:
4.69E-04
Percent of SIL 2 budget:
4.69%
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Appendix
D
Using ControlLogix and FLEX I/O Modules in SIL 1
Applications
Approved 1756 I/O modules may be used in a 1oo1 architecture; however, you
must follow the guidelines listed in Table 14 on page 138.
If you plan to use 1794 FLEX I/O modules in a SIL 1 1oo1 configuration, in
addition to following the guidelines in Table 14, you must also implement
appropriate field diagnostics as defined below:
• Field diagnostics must execute once every eight hours.
• An output or other sensing device must be used to provide field power
control to the digital inputs. See the SIL 2 output guidelines in Chapter 5,
ControlLogix I/O Modules.
• You must consider the time it takes a diagnostic to execute when
determining the safety reaction time because safety demands will not be
detectable if they occur during a diagnostic.
The diagnostic you implement must monitor the ability of all SIL 1 inputs
to detect a change of state. One method would be to turn off the output
and monitor that all SIL 1 inputs detect the loss of signal within a short
period of time. Then, when the output turns back on, make sure that all
SIL 1 inputs properly detect the change. You need to consider and mitigate
any impact to your system while the diagnostic is executing.
Figure 64 - SIL 1 Digital Input Wiring Example for 1794 I/O Modules
Field Power
Field Devices
1
SIL1 Input 1
SIL1 Output
2
SIL1 Input 2
3
SIL1 Input 3
TIP
Field diagnostics as described for 1794 I/O modules can also be used to meet
the requirements for periodic proof testing with either 1794 or 1756 I/O
modules.
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
135
Appendix D
Using ControlLogix and FLEX I/O Modules in SIL 1 Applications
Termination boards 1492-TIFM16-F-3 can be used to provide a voltage reference
for periodic testing as shown below.
Figure 65 - SIL 1 1756 Analog Input Wiring Example (Simplex)
1756 Analog Input Module
Input Values from Field Devices
All configured for 0...5V operation.
1492-CABLExxxUA(1) to 1756
Analog Input Module
1756 Analog Input
Module
Solid-state switch controlled
by DC output.
Reference Voltages
DIP Switch for Sensor
Wiring
Precision 249 :
Resistor
Terminal Block 1,
Row C
Terminal Block 2,
Row C
Terminal Block 1,
Row B
Terminal Block 2,
Row B
Two-wire Transmitters Operating in
4...20 mA Current Mode
Two-wire Transmitter
Output from 1756-OB16D Module Pair
Trigger Reference Tests = 0 (Off)
xxx is cable length (005=0.5 m, 010=1.0 m, 025=2.5 m, 050=5.0 m).
136
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Using ControlLogix and FLEX I/O Modules in SIL 1 Applications
Appendix D
Figure 66 - SIL 1 1794 Analog Input Wiring Example (Simplex)
1756 Analog Input Module
Input Values from Field Devices
All configured for 0...5V operation.
Solid-state switch controlled
by DC output.
User-supplied cable
Reference Voltages
DIP Switch for Sensor
Wiring
Precision 249 :
Resistor
Terminal Block 1,
Row C
Terminal Block 1,
Row B
Terminal Block 2,
Row C
Terminal Block 2,
Row B
Two-wire Transmitters Operating in
4...20 mA Current Mode
Two-wire Transmitter
Output from 1756-OB16D Module Pair
Trigger Reference Tests = 0 (Off)
To make your own cable, follow the termination board pinout shown below.
P1 Pins
Description
3
Input 0
2
Input 1
1
Input 2
14
Input 3
15
Input 4
16
Input 5
17
Input 6
18
Input 7
12
Input 8
13
Input 9
25
Input 10
24
Input 11
23
Input 12
22
Input 13
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
137
Appendix D
Using ControlLogix and FLEX I/O Modules in SIL 1 Applications
P1 Pins
Description
20
Input 14
21
Input 15
4
RTN
6
RTN
8
RTN
10
RTN
When using controllers and network communication modules, follow the
guidelines listed in this safety manual.
IMPORTANT
When using 1756 or 1794 outputs in SIL 1 configurations, you must implement
a secondary means to shut off the outputs.
Table 14 lists additional considerations that must be made with various
ControlLogix modules in a SIL1 application.
Table 14 - Considerations for SIL1 Applications by Module
Module
Additional considerations
Controllers
None. Use the controller exactly as described previously in this manual.
ControlNet modules
None. Use the modules exactly as described previously in this manual.
Ethernet modules
None. Use the modules exactly as described previously in this manual.
Digital output modules(1)
Diagnostic output modules are recommended in a SIL1 application. Implement a secondary shutdown path if the SIL1 application requires a
fail-safe OFF in the event of a shorted output.
Digital input modules(2)
Only one module is required in a SIL1 application. Periodic tests of the inputs should be performed as described previously in this manual.
Analog output modules(1)
Analog output modules should be wired as described previously in this manual.
(2)
Analog input modules
Only 1 module is required in a SIL1 application. Periodic tests of the inputs should be performed as described previously in this manual.
(1) The user should be alerted to any detected output failures.
(2) The test interval of module inputs must be specified according to application-dependent standards. For example, according to EN50156, the time for fault detection and tripping must be less than or equal
to the fault tolerance time.
138
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Appendix
E
Checklists
Checklist for the ControlLogix
System
Topic
Page
Checklist for the ControlLogix System
139
Checklist for SIL Inputs
140
Checklist for SIL Outputs
142
Checklist for the Creation of an Application Program
143
The following checklist is required for planning, programming and start up of a
SIL 2-certified ControlLogix system. 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.
Check List for ControlLogix System(1)
Company:
Site:
Loop definition:
No.
Fulfilled
Yes
1
Are you only using the SIL 2-certified ControlLogix modules with the corresponding firmware release listed in
Revision Release List (available from the Product Certification link at http://www.ab.com) for your safety
application?
2
Have you calculated the system’s response time?
3
Does the system’s response time include both the user-defined, SIL-task program watchdog (software
watchdog) time and the SIL-task duration time?
4
Is the system response time in proper relation to the process tolerance time?
5
Have PFD values been calculated according to the system’s configuration?
6
Have you performed all appropriate proof tests?
7
Have you defined your process parameters that are monitored by fault routines?
8
Have you determined how your system will handle faults?
9
Have you taken into consideration the checklists for using SIL inputs and outputs listed on pages 140 and 142.
Comment
No
(1) For more information on the specific tasks in this checklist, see the previous sections in the chapter or Chapter 1, SIL Policy on page 13.
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
139
Appendix E
Checklists
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 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 Module Check List for ControlLogix System
Company:
Site:
Loop definition:
SIL input channels in the:
No.
All Input Module Requirements (apply to both digital and analog input modules)
1
Is Exact Match selected as the electronic keying option whenever possible?
2
Is the RPI value set to an appropriate value for your application?
3
Are all modules owned by the same controller?
4
Have you performed proof tests on the system and modules?
5
Have you set up the fault routines?
6
Are control, diagnostics and alarming functions performed in sequence in application logic?
7
For applications using FLEX I/O modules, 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
1
When two digital input modules are wired in the same application, do the following conditions exist:
•
•
•
•
•
•
Both modules are owned by the same controller.
Sensors are wired to separate input points.
The operational state is ON.
The non-operational state is. OFF.
Configuration parameters (for example, RPI, filter values) are identical.
For FLEX input modules, both module are on different ControlNet nodes
2
For the standard input modules, is the Communication Format set to one of the Input Data choices?
3
For the diagnostic input modules, is the Communication Format set to Full Diagnostics-Input Data?
4
For the diagnostic input modules, are all diagnostics enabled on the module?
5
For the diagnostic input modules, are enabled diagnostic bits monitored by fault routines?
6
For the diagnostic input modules, is the connection to remote modules a direct connection?
140
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Yes
Yes
No
No
Comment
Comment
Checklists
Appendix E
Input Module Check List for ControlLogix System
No.
Additional Analog Input Module-Only Requirements
1
Is the Communication Format set to Float Data?
2
Have you calibrated the modules as often as required by your application?
3
Are you using ladder logic to compare the analog input data on two channels to make sure there is concurrence within
an acceptable range and that redundant data is used properly?
4
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?
5
When two FLEX I/O analog input modules are wired in the same application, are both module on different ControlNet
nodes?
6
When wiring an analog input module in Voltage mode, are transmitter grounds tied together?
7
When wiring an analog input module in Current mode, are loop devices placed properly?
8
When wiring thermocouple modules in parallel, have you wired to the same channel on each module as shown in
Figure 33 on page 64?
9
When wiring two RTD modules, are two sensors used, as shown in Figure 34 on page 65?
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Yes
No
Comment
141
Appendix E
Checklists
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 System
Company:
Site:
Loop definition:
SIL output channels in the:
No.
All Output Module Requirements
(apply to both digital and analog output modules)
1
Have you performed proof tests on the modules?
2
Is Exact Match selected as the electronic keying option whenever possible?
3
Is the RPI value set to an appropriate value for your application?
4
Have you set up fault routines, including comparing output data with a corresponding input point?
5
If required, have you used external relays in your application to disconnect module power if a short or other
fault is detected on the module or isolated output in series?
6
Is the control of the external relay implemented in ladder logic?
7
Have you examined the Output Data Echo signal in application logic?
8
Are all outputs configured to de-energize in the event of a fault or the controller entering Program mode?
9
Do two modules of the same type, used in the same application, use identical configurations?
10
Does one controller own both modules if two of the same type are used in an application?
11
Are control, diagnostics and alarming functions performed in sequence in application logic?
No.
Digital Output Module-Only Requirements
1
For the standard output modules, is the Communication Format set to Output Data?
2
For standard output modules, have you wired the outputs to a corresponding input to validate that the output
is following its commanded state?
3
For the diagnostic output modules, are all diagnostics enabled on the module?
4
For the diagnostic output modules, are enabled diagnostic bits monitored by fault routines?
5
For the diagnostic output modules, is the Communication Format set to Full Diagnostics-Output Data?
6
For diagnostic output modules, have you periodically performed a Pulse Test to make sure that the output is
capable of change state?
7
For diagnostic output modules, is the connection to remote modules a direct connection?
142
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Yes
No
Comment:
Yes
No
Comment
Checklists
Appendix E
Output Check List for ControlLogix System
No.
Analog Output Module Requirements - Analog Only
1
Is the Communication Format set to Float Data?
2
Have you calibrated the modules as often as required by your application?
3
When wiring an analog output module in Current mode, are loop devices placed properly?
4
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?
Checklist for the Creation of
an Application Program
Yes
No
Comment
The following checklist is recommended to maintain safety technical aspects
when programming, before and after loading the new or modified program.
Checklist for Creation of an Application Program
Safety Manual ControlLogix System
Company:
Site:
Project definition:
File definition / Archive number:
Notes / Checks
Yes
No
Comment
Before a Modification
Are the configuration of the ControlLogix system and the application program created on
the basis of safety aspects?
Are programming guidelines used for the creation of the application program?
After a Modification - Before Loading
Has a review of the application program with regard to the binding system specification
been carried out by a person not involved in the program creation?
Has the result of the review been documented and released (date/signature)?
Was a backup of the complete program created before loading a program in the
ControlLogix system?
After a Modification - After Loading
Was a sufficient number of tests carried out for the safety relevant logical linking (including
I/O) and for all mathematical calculations?
Was all force information reset before safety operation?
Has it been verified that the system is operating properly?
Have the appropriate security routines and functions been installed?
Is the controller keyswitch in Run mode and the key removed?
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
143
Appendix E
Checklists
Notes:
144
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
Index
Numerics
1oo1 architecture 135
1oo1 configuration 118
1oo2 configuration 118
1-year PFD calculations 119
2-year PFD calculations 124
5-year PFD calculations 129
A
actuators 93
Add-On Instructions 49, 90
alarms
1756 analog input modules 58, 101
analog input modules
See ControlLogix analog input modules.
See FLEX I/O analog input modules.
analog output modules
See ControlLogix analog output modules.
See FLEX I/O analog output modules.
application program
programming languages 90
SIL task/program instructions 94
applications
boiler 16
combustion 16
gas and fire 14
B
boiler applications 16
C
cable
ControlNet network 44
calculations
1-year PFD 119
2-year PFD 124
5-year PFD 129
explanation of 118
PFD 117
calibrate
1756 analog input modules 58
1756 analog output modules 67
1794 analog input modules 78
1794 analog output modules 84
certification 31
change parameters 104
channel status
monitoring 59, 68
chassis 41
chassis adapter 41
checklists 139
CIP. See Control and Information Protocol.
CL SIL 2 31
combustion applications 16
commissioning life cycle 96
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
communication
ControlNet components 44
data echo 34
Data Highway Plus - Remote I/O components
45
EtherNet/IP components 45
field-side output verification 34
network 36
requirements 46
output data echo 53
SynchLink modules 45
compliances 31
components
1756 chassis 41
1756 power supply 41
FLEX I/O 115-116
configurations
fail-safe 17
fault-tolerant 25
high-availability 24
connections
direct 51
rack-optimized 51
Control and Information Protocol (CIP) 9
control function
specification 92
CONTROLLERDEVICE object 101
controllers
requirements 40
ControlLogix
analog input modules
alarms 58, 101
calibrate 58
ownership 60
wiring 60
analog output modules
calibrate 67
ownership 69
wiring 69
digital input modules
requirements 51
wiring 51
digital output modules
requirements 53
wiring 54
RTD input modules
wiring 64
thermocouple input modules
wiring 64
ControlNet communication modules
diagnostic coverage 44
ControlNet network 36
1756 communication modules 43
1756 components 44
cable 44
repeater module 44
coordinated system time 45
D
data echo 34, 53
145
Index
Data Highway Plus - Remote I/O 43
components 45
network 43, 45
DCS. See Distributed Control System
DH+. See Data Highway Plus.
DHRIO. See Data Highway Plus - Remote I/O
diagnostic coverage
ControlNet communication modules 44
defined 9
digital input modules
See ControlLogix digital input modules.
See FLEX I/O digital input modules.
digital output modules
See ControlLogix digital output modules.
See FLEX I/O digital output modules.
direct connection 51
Distributed Control System 45
duplex configurations 17
enhanced availability 49
fault-tolerant
safety loop 25
fault-tolerant systems 17
logic solver 17
safety loop 24
E
edit
application program 97, 98
emergency shutdown applications 13, 14, 17,
54, 68
EN 50156 16
ESD. See emergency shutdown (ESD)
applications.
EtherNet/IP network 37
1756 communication modules 43
components 45
F
fail-safe configuration
about 17
fault detection 99-101
fault handling
additional resources 102
detection of faults 99-101
fault reporting 33, 100
1794 analog input modules 78
1794 analog output modules 85
1794 digital input modules 74
1794 digital output modules 75, 76
additional resources 102
detection of faults 99-101
fault-tolerant configuration 25
field devices
testing 51
field-side output verification 34
fire
considerations for 14
146
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
FLEX I/O
analog input modules
calibrate 78
wiring 80
analog output modules
calibrate 84
wiring 87
components 115-116
digital input modules
wiring 74
digital output modules
wiring 76
EN 50156 standard 16
module fault reporting 74, 75, 76, 78, 85
RTD input modules
wiring 83
terminal base units 116
thermocouple input modules
wiring 82
floating-point data format 58, 67
forcing via software 94
G
gas and fire applications 14
Get System Value (GSV)
defined 9
keyswitch position 101
GSV. See Get System Value (GSV).
H
hardware
1756 chassis 41
1756 power supply 41
HART analog input modules 65-66
wiring 65
HART analog output modules 71
wiring 71
high-availability configuration 24
HMI
changing parameters via 104
devices 17, 46, 103
use and application 103-105
hold last state 14
I
I/O modules
calibrate 58
fault reporting 100
proof test
1756 analog input modules 58
1756 analog output modules 67
1756 digital input modules 51
1756 digital output modules 53
1794 analog output modules 84
1794 digital input modules 73
1794 digital output modules 75
wiring
1756 analog input modules 60
1756 analog output modules 69
Index
1756 digital input modules 51
1756 digital output modules 54
1756 RTD input modules 64
1756 thermocouple input modules 64
1794 analog input modules 80
1794 analog output modules 87
1794 digital input modules 74
1794 digital output modules 76
1794 RTD input modules 83
1794 thermocouple input modules 82
HART analog input modules 66
HART analog output modules 71
IEC 61131-3 89
IEC 61508 13, 28, 118
IEC 61511 13, 97, 98, 105
interface
HMI use and application 103-105
K
KEYSTATE word 101
keyswitch 35, 40, 91
checking position 100
L
life cycle
commissioning 96
logic
developing 93
Logix CPU Security 90
M
manual override circuit 15
Mean Time Between Failures (MTBF)
defined 9
Mean Time To Restoration (MTTR)
defined 10
modes 39
module fault reporting 33, 100
monitor
channel status 59, 68
motion 94
MTBF. See Mean Time Between Failures
(MTBF).
MTTR. See Mean Time To Restoration.
N
network update time 31
NFPA 85, NFPA 86 16
O
operating modes 39
output data echo
digital outputs and 53
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
ownership
1756 analog input modules 60
1756 analog output modules 69
1756 digital input modules 51
1756 digital output modules 54
P
PADT. See Programming and Debugging Tool.
parameters
changing 104
reading 103
peer-to-peer communication 43
requirements 46
PFD. See Probability of Failure on Demand.
position
keyswitch 100
power supply 41
redundant 41
Probability of Failure on Demand (PFD)
1-year calculations 119
2-year calculations 124
5-year calculations 129
calculations 117, 118
defined 10
values 118
produce and consume data 47
program
changes 97
development life cycle 96
editing 97
edits 97, 98
identification 94
language 90, 93
logic 93
online 97
SIL 2 89
Programming and Debugging Tool (PADT) 14,
89
defined 10
proof test 28, 73, 75, 84
1756 analog input modules 58
1756 analog inputs 58
1756 analog output modules 67
1756 analog outputs 67
1756 digital inputs 51
1756 digital output modules 53
1756 digital outputs 53
redundancy systems 29
pulse test 35
R
reaction time 30
See also worst-case reaction time.
reading parameters 103
repeater modules 44
reporting
module faults 33
requested packet interval 33
response time 30, 107-110
147
Index
routine source protection 90
RS AssetCentre 90
RSLogix 5000 software 35
commissioning life cycle 96
editing in 98
forcing 94
general requirements 89-143
program changes 97
programming languages 90
security 90
SIL 2 programming 89
SIL task/program instructions 94
RSNetWorx for ControlNet software 36
RTD input module
See ControlLogix RTD input module.
See FLEX I/O RTD input module.
S
safety certifications 31
safety instrumentation system (SIS)
safety task
See SIL task.
safety watchdog 31
security via software 90
sensors 93
serial
communication 36
port 36
SIL 1 applications 135
SIL 2
certification 31
nonredundant system components 112
programming 89
safety data 47
SIL task 94
simplex configurations 17
safety loop 17
SIS. See safety instrumentation system (SIS).
software
commissioning life cycle 96
forcing 94
general requirements 89-143
program changes 97
programming languages 90
RSLogix 5000 35
security 90
SIL 2 programming 89
SIL task/program instructions 94
watchdog 31
switchover 29, 30, 31
148
Rockwell Automation Publication 1756-RM001L-EN-P - July 2014
SynchLink modules 43, 45
system PFD
example 134
system validation test
See proof test.
T
tags 91
terminal base units
FLEX I/O 116
tests
1756 analog input modules 58
1756 analog output modules 67
1756 digital output modules 53
application logic 94
field devices 51
proof 28
pulse 35
thermocouple input module
See ControlLogix thermocouple input module.
See FLEX I/O thermocouple input module.
V
verify
download and operation 95
W
watchdog 31
wiring
1756 analog input modules 60
1756 analog output modules 69
1756 digital input modules 51
1756 digital output modules 54
1756 RTD input modules 64
1756 thermocouple input modules 64
1794 analog input modules 80
1794 analog output modules 87
1794 digital input modules 74
1794 digital output modules 76
worst-case reaction time 30, 107
analog modules 110
digital modules 108
X
XT components 115
ControlLogix 115
FLEX I/O 115, 116
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Publication 1756-RM001L-EN-P - July 2014
Supersedes Publication 1756-RM001K-EN-P - March 2014
Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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