Safety Reference Manual - Rockwell Automation

1 using controllogix in sil 2 ApplicationsControlLogix 5560 and 5570 ControllersSafety Reference ManualOriginal InstructionsImportant User InformationRead 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 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 this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be no event will Rockwell Automation , Inc.

2 Be responsible or liable for indirect or consequential damages resulting from the use or application of this 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 patent liability is assumed by Rockwell Automation , Inc. with respect to use of information, circuits, equipment, or software described in this of the contents of this Manual , in whole or in part, without written permission of Rockwell Automation , Inc.

3 , is prohibitedThroughout this Manual , when necessary, we use notes to make you aware of Safety may also be on or inside the equipment to provide specific precautions. 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 : 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 information that is critical for successful application and understanding of the HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash.

4 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). Rockwell Automation Publication 1756-RM001O-EN-P - March 20173 Table of ContentsSummary of ChangesNew and Updated Information.. 7 PrefaceTerminology .. 9 Additional Resources .. 11 Chapter 1 SIL PolicyIntroduction to Safety Integrity Level (SIL) .. 13 Programming and Debugging Tool (PADT) .. 14 About the controllogix system .. 14 Gas and Fire Considerations.. 15 Boiler and Combustion Considerations.

5 16 Typical sil 2 Configurations .. 17 Simplex Configuration .. 17 Duplex Logic-Solver Configurations .. 27 Duplex system Configuration .. 31 Proof Tests .. 33 Proof Testing with Redundancy Systems .. 33 Reaction Times .. 34 Reaction Times in Redundancy Systems.. 34 Safety Watchdog .. 35 Safety Certifications and Compliances .. 35 Chapter 2 Features of the controllogix sil 2 SystemModule Fault Reporting .. 38 Data Echo Communication Check .. 38 Pulse Test .. 39 Software .. 39 Communication .. 41 Communication Ports .. 41 ControlNet Network .. 41 EtherNet/IP Network.

6 42 Electronic Keying of Modules in sil 2 Applications.. 42 Chapter 3 controllogix Controllers, Chassis, and Power SuppliesControlLogix Controllers .. 43 Operating Modes .. 43 Requirements for Use .. 44 controllogix Chassis.. 45 controllogix Power Supplies .. 45 Redundant Power Supplies .. 45 Recommendations for using Power Supplies.. 464 Rockwell Automation Publication 1756-RM001O-EN-P - March 2017 Table of ContentsChapter 4 controllogix Communication ModulesIntroduction to Communication Modules .. 47 ControlNet Modules and Components .. 48 ControlNet Cabling.

7 48 ControlNet Repeater .. 48 ControlNet Module Diagnostic Coverage .. 48 EtherNet/IP Communication Modules .. 49 DeviceNet Scanner .. 49 Data Highway Plus - Remote I/O Module (1756-DHRIO) .. 49 SynchLink Module .. 49 General Requirements for Communication Networks .. 50 Peer-to-peer Communication Requirements.. 50 Additional Resources .. 51 Chapter 5 controllogix I/O ModulesOverview of controllogix I/O Modules.. 54 using 1756 Digital Input Modules.. 56 Requirements When using Any controllogix Digital Input Module .. 56 Wiring controllogix Digital Input Modules.

8 57 using 1756 Digital Output Modules .. 58 Requirements When using controllogix Digital Output Modules 58 Wiring controllogix Digital Output Modules.. 60 using 1756 Analog Input Modules .. 64 Conduct Proof Tests.. 64 Calibrate Inputs .. 64 Use the Floating Point Data Format .. 64 Program to Respond to Faults Appropriately.. 65 Program to Compare Analog Input Data .. 65 Configure Modules .. 66 Specify the Same Controller as the Owner .. 66 Wiring controllogix Analog Input Modules .. 67 using 1756 HART Analog Input Modules .. 72 Wiring the HART Analog Input Modules.

9 72 using 1756 Analog Output Modules .. 73 Considerations for using Analog Output Modules .. 73 Wiring controllogix Analog Output Modules .. 75 using 1756 HART Analog Output Modules .. 78 Wiring the HART Analog Output Modules .. 78 Rockwell Automation Publication 1756-RM001O-EN-P - March 20175 Table of ContentsChapter 6 FLEX I/O ModulesOverview of FLEX I/O Modules .. 79 using 1794 Digital Input Modules.. 79 Requirements When using FLEX I/O Digital Input Modules 79 Wiring FLEX I/O Digital Input Modules .. 80 using 1794 Digital Output Module .. 81 Considerations When using FLEX I/O Digital Output Modules 81 Wiring FLEX I/O Digital Output Modules.

10 82 using 1794 Analog Input Modules .. 83 Considerations When using FLEX I/O Analog Input Modules 83 Wiring FLEX I/O Analog Input Modules .. 86 using 1794 Analog Output Modules .. 90 Requirements When using FLEX I/O Analog Output Modules 90 Wiring FLEX I/O Analog Output Modules .. 93 Chapter 7 Requirements for Application DevelopmentSoftware for sil 2 -Related Systems .. 95 sil 2 Programming.. 95 Programming Languages .. 96 Programming Options .. 96 Security .. 97 Basics of Application Program Development and Testing .. 98 Functional Specification Guidelines.