Allen-Bradley GuardPLC 1753 User manual

GuardPLC™

Controller Systems

Bulletin 1753, 1754, and 1755

Safety Reference Manual

AB Parts

Important User Information

Solid state equipment has operational characteristics differing from those of

electromechanical equipment. Safety Guidelines for the Application,

Installation and Maintenance of Solid State Controls (Publication SGI-1.1

available from your local Rockwell Automation sales office or online at

http://www.ab.com/manuals/gi) describes some important differences

between solid state equipment and hard-wired electromechanical devices.

Because of this difference, and also because of the wide variety of uses for

solid state equipment, all persons responsible for applying this equipment

must satisfy themselves that each intended application of this equipment is

acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for

indirect or consequential damages resulting from the use or application of

this equipment.

The examples and diagrams in this manual are included solely for illustrative

purposes. Because of the many variables and requirements associated with

any particular installation, Rockwell Automation, Inc. cannot assume

responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to

use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without

written permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual we use notes to make you aware of safety

considerations.

Allen-Bradley, GuardPLC, and RSLogix Guard PLUS are trademarks of Rockwell Automation.

WindowsNT and Windows 2000 are registered trademarks of Microsoft Corporation.

WARNING Identifies information about practices or circumstances

that can cause an explosion in a hazardous environment,

which may lead to personal injury or death, property

damage, or economic loss.

IMPORTANT Identifies information that is critical for successful

application and understanding of the product.

ATTENTION Identifies information about practices or circumstances

that can lead to personal injury or death, property

damage, or economic loss. Attentions help you:

•identify a hazard

•avoid a hazard

•recognize the consequence

iii Publication 1755-RM001B-EN-P - March 2004

Summary of Changes

The information below summarizes the changes to this manual since

the last publication.

To help you find new and updated information in this release of the

manual, we have included change bars as shown to the right of this

paragraph.

Information regarding GuardPLC 1600 and GuardPLC 1800 controllers,

GuardPLC Distributed I/O, and RSLogix Guard PLUS programming

software has been added throughout the manual. The table below

summarizes other changes since the last publication.

For information about See

List of catalog numbers covered by this safety reference

manual

page 1-1

Certification page 1-2

PFD and PFH calculations page 1-3

Safety requirements page 1-3

Programming requirements page 1-4

Communication requirements page 1-5

Maintenance override page 1-5

Updated power supply requirements page 2-1

Updated table of GuardPLC input capabilities page 3-1

Preventing surge impulses on digital inputs page 3-4

Configurable digital inputs page 3-4

Line control for inputs page 3-4

Analog input values for GuardPLC 1800 page 3-6

Revised checklist for safety-related inputs page 3-10

Updated table of GuardPLC output capabilities page 4-1

Line control for outputs page 4-3

Revised checklist for safety-related outputs page 4-6

Revised checklist for creation of the application program page 5-8

Configuring communications Chapter 7

Use in central fire alarm systems Appendix B

AB Parts

Publication 1755-RM001B-EN-P - March 2004

Summary of Changes iv

vPublication 1755-RM001B-EN-P - March 2004

Table of Contents

Chapter 1

Safety Concept

Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Introduction to Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

PFD and PFH Calculations . . . . . . . . . . . . . . . . . . . . . . 1-3

Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hardware Configuration. . . . . . . . . . . . . . . . . . . . . . . . 1-3

Programming Requirements . . . . . . . . . . . . . . . . . . . . . 1-4

Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Maintenance Override . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Safety Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Fault Tolerance Time (FTT) . . . . . . . . . . . . . . . . . . . . . 1-6

Safety Time (of the PES). . . . . . . . . . . . . . . . . . . . . . . . 1-6

Multiple Error Occurrence Time (MOT) . . . . . . . . . . . . 1-6

Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Watchdog Time of the CPU (in the PES) . . . . . . . . . . . . 1-7

Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Chapter 2

Central Functions

Chapter Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Power Supply Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Functional Description of the Central Processing Unit. . . . . 2-2

Self-Test Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Microprocessor-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Test Memory Sectors . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Fixed Memory Sectors . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

RAM-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Watchdog-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Test of the I/O Bus Within the System . . . . . . . . . . . . . 2-4

Reactions to Detected Errors in the CPU . . . . . . . . . . . . 2-4

Error Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Chapter 3

Input Channels

Chapter Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

General Information on Safety-Related Input Modules . . . . 3-2

Safety of Sensors, Encoders, and Transmitters. . . . . . . . . . . 3-2

Safety-Related Digital Inputs and Input Modules. . . . . . . . . 3-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Test Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Reaction To Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Surge on Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Configurable Digital Inputs. . . . . . . . . . . . . . . . . . . . . . 3-4

Line Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

AB Parts

Publication 1755-RM001B-EN-P - March 2004

Table of Contents vi

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Test Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Reaction In Case of Fault . . . . . . . . . . . . . . . . . . . . . . . 3-8

Counter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Test Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Reaction In Fault Condition . . . . . . . . . . . . . . . . . . . . . 3-9

Checklist for Safety-Related Inputs . . . . . . . . . . . . . . . . . . . 3-10

Chapter 4

Output Channels

Chapter Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Overview of GuardPLC Output Modules . . . . . . . . . . . . . . 4-1

General Safety Information On Safety-Related

Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Test Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Reaction To Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Line Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Analog Outputs in the 1755-OF8 (AB-AO) . . . . . . . . . . . . . 4-4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Test Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Reaction To Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Checklist for Safety-Related Outputs. . . . . . . . . . . . . . . . . . 4-6

Chapter 5

GuardPLC Controller Operating

System

Chapter Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Software for GuardPLC Safety-Related Systems . . . . . . . . . . 5-1

Technical Safety for the Operating System . . . . . . . . . . . . . 5-2

Operation Mode and Functions of the Operating System . . 5-2

Technical Safety

for Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Safety Concept of RSLogix Guard PLUS. . . . . . . . . . . . . 5-3

Check the Application Program . . . . . . . . . . . . . . . . . . 5-3

Creation of a Backup Program . . . . . . . . . . . . . . . . . . . 5-4

Program Identification . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Parameters of the Automation System . . . . . . . . . . . . . . . . 5-5

Forcing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Protection Against Manipulation . . . . . . . . . . . . . . . . . . . . 5-7

Checklist for the Creation of an Application Program . . . . . 5-8

Publication 1755-RM001B-EN-P - March 2004

Table of Contents vii

Chapter 6

Technical Safety for the

Application Program

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Basis of Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Combinatory Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Sequential Controls (Step Controls). . . . . . . . . . . . . . . . 6-3

Sensors (Digital or Analog). . . . . . . . . . . . . . . . . . . . . . 6-3

Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Variable Declaration and

I/O Naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Assignment of I/O Names to Variable Names . . . . . . . . 6-4

Types of Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Functions of the Application Program . . . . . . . . . . . . . . . . 6-5

Safety-Related Inputs and Outputs . . . . . . . . . . . . . . . . 6-5

Parameters of the Application Program . . . . . . . . . . . . . 6-6

Procedure for “Disabling” the PES . . . . . . . . . . . . . . . . 6-6

Procedure for “Enabling” the PES . . . . . . . . . . . . . . . . . 6-7

Code Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Loading and Starting the Application Program. . . . . . . . 6-8

Forcing Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . 6-8

Program Documentation for Safety-Related Applications . . . 6-9

Chapter 7

Configuring Communications

Non-Safety-Related Communication . . . . . . . . . . . . . . . . . . 7-1

Safety-Related (Peer-to-Peer) Communication. . . . . . . . . . . 7-1

Calculating Worst-Case Reaction Time . . . . . . . . . . . . . 7-2

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Appendix A

Specifications

Chapter Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Climatic Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Mechanical Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

EMC Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Power Supply Conditions . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Appendix B

Use in Central Fire Alarm Systems

AB Parts

Publication 1755-RM001B-EN-P - March 2004

Table of Contents viii

1Publication 1755-RM001B-EN-P - March 2004

Chapter

Safety Concept

This chapter introduces you to the safety concept for the following

GuardPLC products:

Catalog Number Description

1753-L28BBB-M GuardPLC 1600 controller with Modbus Communications

1753-L28BBB-P GuardPLC 1600 controller with Profibus-DP Communications

1753-L32BBBM-8A GuardPLC 1800 controller with Modbus Communications

1753-L32BBBP-8A GuardPLC 1800 controller with Profibus-DP Communications

1753-IB16 GuardPLC 16-point Input Module

(for GuardPLC 1600 or 1800 controllers)

1753-IB20XOB8 GuardPLC I/O Module

(for GuardPLC 1600 or 1800 Controllers)

1753-OB16 GuardPLC 16-point Output Module

(for GuardPLC 1600 or 1800 Controllers)

1754-L28BBB GuardPLC 1200 Controller

1755-L1 GuardPLC 2000 Controller

1755-A6 GuardPLC 2000 I/O Chassis

1755-IB24XOB16 GuardPLC 2000 Digital I/O Module

1755-IF8 GuardPLC 2000 Analog Input Module

1755-HSC GuardPLC 2000 High Speed Counter Module

1755-OF8 GuardPLC 2000 Analog Output Module

1755-PB720 GuardPLC 2000 Power Supply Module

For information about: See page:

certification 1-2

introduction to safety 1-2

safety requirements 1-3

safety times 1-5

terminology used in this manual 1-7

AB Parts

Publication 1755-RM001B-EN-P - March 2004

1-2 Safety Concept

Certification

Certificate No. 968/EZ164.00/04

TÜV Rheinland/Berlin-Brandenburg

TÜV Anlagentechnik GmbH

Automation, Software, and Informatinstechnologie

Safety restrictions can be found in this manual. See Safety

Requirements on page 1-3.

Introduction to Safety

The Programmable Electronic System (PES) for the Allen-Bradley

GuardPLC system is safety-related, based on the 1oo2 microprocessor

structure for one central module. These controllers are safety-related

up to safety requirement class 6 according to DIN V 19250, SIL 3

according to IEC 61508 and category 3,4 according to EN 954-1.

Safety tests are based on the safety standards current at the time of

certification. These safety tests consist of test routines that are run

during the entire operating phase. The routines are guaranteed to the

highest degree of safe function for existing systems, making the PES

suitable for the Safety Machinery Market.

For support in the creation of safety-related programs, use the

programming software RSLogix Guard PLUS, according to IEC

61131-3. (Programming software is defined in IEC 61131-1.)

The PES has been designed to the closed-circuit current principle,

which requires that systems be designed so that the “normally closed”

or “on” state of external sensors and actuators is the normal run

condition. The “off” or “normally open” state is the safe state. This

means that in the event of a fault or safety trip, all inputs and outputs

revert to the “off” (current-free/voltage free) state.

This manual suits for next models

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