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Modicon Quantum Safety PLC Reference Manual - Barr

1. 110 Checklist for Programming SIL3 Applications 112 Checklist for VO Modules sssisdseeeee e a En RE Rn RR RES ER 114 Checklist for Operation Maintenance and Repair 116 Chapter 5 Special Requirements for Application Standards 119 Special Requirements for Application Standards 119 ADDOlUICBS 6 02 60 eiaa ae dex ER GRE une Pump Koss 121 Appendix A IEC 61508 ssssee nnn 123 General Information on the IEC 61508 005 124 MI HO PPPITTR 126 Appendix B System Objects lsslsss 131 B System BIS 2205 preissii kiei ee Pa rea dq e Rede RE ES 132 System Bit IntroduoliGIT saoter arcere tarag kie E WRTOT ERR SS 133 Description of the System Bits S0 to S13 20 00005 134 Description of the System Bits S15 to S21 0 000 136 Description of the System Bits S30 to S51 00006 138 Description of the System Bits 96859 to 968122 Lulu 139 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com B 2 System Words Description of the System Words SWO to SW21 22 142 Description of the System Words SW30 to SW59 145 Description of the System Words 6SW60 to SW127 148 GlOSSA lV sasaaa es ES RR Ead adr Besa d wp os ER oer 155 Index
2. BLKERRTYPE last fault detected The code of the last fault detected is given in this word The following error codes cause the PLC to stop if S78 is setto 1 815 818 and S20 are activated independently of S78 e 1640002 PCMCIA signature not verified e 1642258 execution of HALT instruction e 16342302 call to a not supported system function in a user function block e 1639690 error of application CRC detected in background e 16 DE87 calculation error on floating point numbers 918 these errors are listed in the word SW17 e 16 DEBO watchdog overflow 5811 e 16 DEF1 character string transfer error 815 e 16 DEF2 arithmetic or division by O error 818 e 16 DEF3 index overflow 920 Note The codes 16 8xxx and 16 7xxx do not stop the application and indicate an error on function blocks In case of a SIL3 related error the PLC stops After power off and restart of the PLC SW 125 contains the code of the cause of the error Ox5AF1 sequence check error unpredictable execution in CPU Ox5AF2 error in memory corrupt address Ox5AF3 comparison error execution results of Intel and application processor differ Ox5AF4 real time clock error Ox5AF5 error initializing double code execution Ox5AF6 watchdog activation error Ox5AFT error during memory check takes more than 8 hours Ox5AF8 error in memory check corrupt RAM Note 5W1
3. Functional Safety Parameters The Functional Safety parameters according to EN ISO 13849 are as follows e Performance Level for e SDI to SDO PL d e SAI to SDO PL d e Category 3 Available Non Interfering Products Schneider Electric offers the following non interfering products Module Type Module Reference Remote I O Head Adapter 140 CRP 932 00 Remote I O Drop Adapter 140 CRA 932 00 Ethernet Module 140 NOE 771 11 Backplane 16 Slots 140 XBP 016 00 Backplane 10 Slots 140 XBP 010 00 Backplane 6 Slots 140 XBP 006 00 Digital Input 140 DDI 353 00 Digital Output 140 DDO 353 00 Analog Input 140 ACI 040 00 Analog Output 140 ACO 020 00 Terminal Strip 140 XTS 001 00 Terminal Strip 140 XTS 002 00 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 4 DANGER LOSS OF THE ABILITY TO CREATE A SAFETY RELATED SYSTEM Choose only Schneider Electric products certified for use in Safety Related Systems if you want to create a Safety Related System Only Safety modules are allowed to perform Safety Functions Make sure that neither inputs nor outputs of non interfering modules are used for Safety Related outputs Failure to follow these instructions will result in death or serious injury Unity Pro XLS offers modularization of the logic into sections Schneider Electric recommends creating s
4. System Objects Word Function Description Initial Write Quant Symbol State Access Safety 96eSW49 real time clock System words containing date and current time in yes yes DAYOFWEEK function BCD e SW49 day of the week SW50 e 1 Monday SEC e 2 Tuesday e 3 Wednesday SW51 e 4 Thursday HOURMIN e 5 Friday e 6 Saturday SW52 e 7 Sunday Renee e SW50 Seconds 16448800 e SW53 SW51 Hours and Minutes 164 HHMM e SW52 Month and Day 16 MMDD ARED e SW53 Year 16 YYYY These words are managed by the system when the bit S50 is set to 0 These words can be written by the user program or by the terminal when the bit S50 is set to 1 146 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Word Function Description Initial Write Quant Symbol State Access Safety SW54 real time clock System words containing date and time of the last no yes STOPSEC function on last power outage or PLC stop in Binary Coded stop Decimal SW55 e SW54 Seconds 00SS STOPH e SW55 Hours and Minutes HHMM e SW56 Month and Day MMDD SW56 e SW57 Year YYYY STOPMD e SW58 the most significant byte contains the day of the week 1 for Monday through to 7 for SW57 Sunday and the least significa
5. 0 0e eens 66 Available Language Sections unanunua auaa 67 Exceptions and Requirements for Programming lusus 68 Process Safety NMG iueclledcesetieu e Rr RARE EY RR REES En 71 3 2 Software Description liliis 76 Unity Pro XLS soe ssnresss oniri sede e RIGu d hie RH ee RN 71 Functions Function Blocks for SIL3 Applications 79 Application Password illllllle rs 83 3 3 Operating Procedures iss esp kE etases E RR RE oe dee ead 84 Operating Modes of the Safety PLC 0 0020000 85 Sra TTE 87 Maintenance Mode cee eee en 89 Forclng scout m epe EDGE run bee Ager E ruri mE 91 3 4 Special Features and ProcedureS 0 ccc eee 93 Checking the Programming Environment sllselsssn 94 Starting the Quantum Safety PLC luullsulsullsllsuss 95 Version Stamp 2 2 00 les 96 UU DIOAG ETT 97 Project BaCkUpSss s24 452244 iow deve wed oe haved nea REY em mes 98 Detected Faults e mecit neren ates tessa DR RE TR Hage Se 4 99 do COMMUNICANOM uas 2 cue Grae eee ied ERD e wed edb ahe race cowed 100 Memory Area 1 eee 101 PC PLC Communication s 22 5 es ror OE PEEERTIEEDET SERES 104 PLC PLC Communication seusccAeie ARE RET eee dee esedenes 105 PLC HMI Communi calor eii veccesre RreIeSterbertiee5 RE 107 Chapter 4 Checklists lll 109 Checklist for Configuring Safety Related Systems
6. 2 0 the remote PLC is not accessible switched off no communication e SW61 4 0 the applications are identical on both PLCs 5W61 5 e 0 the PLC is used as unit A e 1 the PLC is used as unit B 2SW61 7 e 0 same PLC OS version e 1 different PLC OS version 5W61 8 e 0 same Copro OS version e 1 different Copro OS version 5W61 12 e 0 information given by bit 13 is not relevant e 1 information given by bit 13 is valid 5W61 13 e 0 NOE address set to IP e 1 NOE address set to IP 1 5W61 15 e 0 Hot Standby not activated e 1 Hot Standby activated 33003879 01 2010 149 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Word Function Description Initial Write Quant Symbol State Access Safety SW62 transfer word These 2 words may be written by the user in the 0 yes no HSBY_REVERSE first section of the master task They are then SW6E3 transferred automatically from the Standby HSBY_REVERSE processor to update the primary PLC They may be read on the primary PLC and be used as primary application parameters SW70 real time clock System word containing the number of the week yes WEEKOF YEAR function in the year 1 to 52 SW71 position of the This word provi
7. 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Safety Information ZZ Important Information NOTICE Read these instructions carefully and look at the equipment to become familiar with the device before trying to install operate or maintain it The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure The addition of this symbol to a Danger or Warning safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This is the safety alert symbol It is used to alert you to potential A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided can result in death or serious injury 33003879 01 2010 7 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided ca
8. Requirements for the Program Structure You are only allowed to program your SIL3 project in master task MAST task sections You are not allowed e to program FAST TIMER INTERRUPT and AUX tasks In case of an import Unity Pro XLS ignores the objects not allowed and informs you of their existence If you continue the import it is done without the objects that are not allowed which may lead to errors or it may stop if the import is not possible e to use subroutines SR sections to schedule segments e to call remote I Os in parallel A WARNING POSSIBLE LOSS OF THE ABILITY TO PERFORM SAFETY FUNCTIONS Do not use conditional section execution with Unity Pro XLS Failure to follow these instructions can result in death serious injury or equipment damage Requirements for Language Elements You are only allowed to use functions and function blocks FFBs that are certified for use in Safety logic and described in the Unity Pro Safety Block Library You are not allowed to use e derived function blocks DFB s e ST expressions In LD you are not allowed to use halt coils call coils returns operate blocks compare blocks NOTE Though jumps to labels are allowed in FBD and LD Schneider Electric recommends not using them for a better structuring of your Safety logic 68 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Requirements
9. cold start CPU CRC DC DDT Cold start refers to starting the computer from power off central processing unit cyclic redundancy check D diagnostic coverage fractional decrease in the probability of dangerous hardware failures resulting from the operation of the automatic diagnostic tests Definition IEC 61508 The fraction of the possible dangerous failures Ap is divided into failures which are detected by diagnostics and failures which remain undetected p App Apu The diagnostic coverage DC defines the fraction of the dangerous failures which are detected App Ap DC ADUZAp 1 DC The definition may also be represented in terms of the following equation where DC is the diagnostic coverage App is the probability of detected dangerous failures and Xp total is the probability of total dangerous failures gt ADD DC Y ADtota1 derived data type A derived data type is user defined 33003879 01 2010 157 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary DFB derived function block DIO distributed input output DLL dynamic link library E E E PES electrical electronic programmable electronic system Definition IEC 61508 System for control protection or monitoring based on 1 or more electrical electronic programmable electronic E E PE devices This includes elements of the system such as power supplies s
10. This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com PLC HMI Communication Introduction A HMI is allowed to read data from a Safety PLC However it is only allowed to write to the unrestricted memory area of the PLC see also Memory Area page 101 The Quantum Safety PLC is able to communicate with HMIs using the following e Modbus TCP either with CPU or NOE module e Modbus Plus e Modbus RS232 RS485 The communication between PLC and HMI is not configured in Unity Pro XLS Therefore it cannot be controlled by it and the Quantum Safety CPU protects itself against writing from a HMI Write Protection Description The Safety memory area of the Safety PLC is write protected and you are not allowed to write to it If you do not obey this rule the PLC does not execute your write command see also Write Protection Description page 101 Writing in Maintenance Mode Even in Maintenance Mode there is a write protection of the Safety memory area for other PLCs and HMls But with Unity Pro XLS you are able to modify and tune data With Unity Pro XLS it is possible to e modify logic e set values e force values e debug By using the Schneider Electric OPC server OFS or the web server of the PLC it is also possible to modify data in the Safety memory area when in Maintenance Mode 4 WARNING RISK OF PROCESSING FORCED DATA Follow the latest version of the T V document Mainte
11. no restart no restart cold start cold start This document provided by Barr Thorp Electric Co Inc 800 473 9123 25 www barr thorp com Differences Between Standard and Safety PLC OS To meet the requirements of the IEC 61508 standard the operating system OS of the Quantum Safety PLC differs from that of the standard Quantum PLC The following table lists the main differences between a standard Quantum PLC OS and a Safety Quantum PLC OS Feature Standard Quantum PLC OS Quantum Safety PLC OS Warm Start yes no Safety Mode no yes Minimal Time Duration for MAST Execution in Cyclic 3 ms 20 ms Mode Forcing Safety Mode by Locking the Key no yes Display of Mode Indicating Characters on LCD no yes Memory Check no yes Password no yes Safety Analog Input no yes Safety Digital Input no yes Safety Digital Output no yes Meaning of SW12 SW13 no Safety mode MSTR Blocks yes no Global Data Subscribing Ethernet everywhere only in unrestricted area I O Scanner Read Ethernet everywhere only in unrestricted area Global Input and Specific Input Modbus Plus everywhere only in unrestricted area Unrestricted Area for M and MW no yes Notes The Quantum Safety PLCs only perform cold start Thus the application is re initialized at each start The Quantum Safety PLC can run in cyclic or periodic mode Thus there is no difference i
12. 2 7 Configuration Examples Configuration Examples for the Quantum Safety PLC Introduction The Quantum Safety PLC can consist of a local rack and additional remote I O drops All Safety modules on the local and remote racks are in the safety loop The Safety PLC and the Safety I O modules can be configured as either non redundant or redundant Standalone Configuration 1002 HotStandby system The following is an example of a standalone Quantum Safety PLC consisting of a local rack and 3 remote I O drops dH E Local rack oofa ma P P felol U ft joy i fo Remote drops tlt ja tlo I Lire 60 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com The following figure provides the appropriate functional overview Sensor Actuator NOTE Only the Schneider Electric Safety products are certified for use in your Quantum Safety PLC and therefore for processing Safety Related data Non interfering modules such as the Ethernet NOE communication module are only certified for processing non Safety Related data However they are allowed to be part of the Quantum Safety PLC because they cannot interfere with the Safety Related System by their own means Still they are not allowed to execute Safety Functions Further you can connect other necessary devices such as human machine interfaces HMI These devices are not part of the Safety loop because th
13. System Each supervisor is able to handle a possible over voltage by opening its power switch and triggering its reset block which manages transitions between the states of power on and power off and resets both processors when active the field side which is generated by DC to DC converters 2 over and under voltage supervisors that is 1 for each micro processor system If the 2 isolated DC to DC converters generating the power supply to the field side electronics experience a fault the supervisors signal this condition to its particular processor through an isolator the process which is one of the PELV type with a maximum output voltage of 60 V 2 over and under voltage supervisors that is 1 for each micro processor system in the same way as they monitor the DC to DC converters In case of a fault the supervisors signal this condition to the user logic by setting a status bit in order to warn the system of possible inconsistent inputs A DANGER LOSS OF THE ABILITY TO PERFORM SAFETY FUNCTIONS Use the correct process power supply which is a PELV type with a maximum output of 60 V Failure to follow these instructions will result in death or serious injury 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Safety Analog Input Module Architecture The following figure shows the architecture of the Quantum Safety Analog Input mo
14. The PLC Reaction Time is the time which passes between a signal is detected at the input module terminal and the reaction is set at the output module terminal PS power supply PST process safety time The process safety time is defined as the period of time between a failure occurring in EUC or the EUC control system with the potential to give rise to a hazardous event and the occurrence of the hazardous event if the safety function is not performed Definition IEC 61508 QSE environment system qualification R RAM random access memory random hardware failure failure occurring at a random time which results from 1 or more of the possible degradation mechanisms in the hardware Definition IEC 61508 RIO remote input output 164 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary id combination of the probability of occurrence of harm and the severity of that harm Definition IEC 61508 Risk is calculated using the following equation R S H The letters stand for Letter Meaning R risk S extent of the damage H frequency of occurrence of the damage RM requirements management 33003879 01 2010 165 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary RRF risk reduction factor Definition IEC 61508 The risk reduction factor equals 1 PFD Fisk without Fis
15. e Error or Valid Download Halt and application application Safe mode amp autorun Transition only in maintenance mode Operating Mode Identification You can identify the running mode e byaLCD display on the CPU or e by a status bar field on the PLC screen provided by Unity Pro XLS The LCD display on the CPU indicates the current operating mode by showing the letters M for Maintenance Mode or S for Safety Mode The status bar field on the PLC screen indicates the current operating mode as shown in the following figure rcgi P 12702 1 MANT ENANCE HSB Y A Offine in 4 Cole eur P ovn cars 86 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Safety Mode Safety Mode Description The Safety Mode is the default mode of the Quantum Safety PLC It is a restricted mode in which modifications and maintenance activities are prohibited Safety Mode Restrictions When the PLC is running in Safety Mode the following restrictions are implemented by Unity Pro XLS e Download changes are not allowed e Setting and forcing of Safety variables and Safety I Os is not allowed e Debugging with breakpoints watch points and single step is not allowed e Animation tables and operator screens must not write Safety variables and Safety I Os e The Safety memory is write protected that means that human machine interfaces HMIs and other PLCs cannot write to it
16. emptying of an already empty register It must be tested by the user program after each operation where there is a risk of overflow and then reset to 0 by the user if there is indeed an overflow When the 96818 bit switches to 1 the application stops in error state if the S78 bit has been set to 1 96919 task period Normally set to O this bit is set to 1 by the system in the O yes yes OVERRUN overrun event of a time period overrun i e task execution time periodical is greater than the period defined by the user in the scanning configuration or programmed into the SW word associated with the task The user must reset this bit to 0 Each task manages its own 96919 bit 136 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Bit Symbol Function Description Initial State Write Access Quant Safety 20920 INDEXOVF Index overflow Normally set to O this bit is set to 1 when the address of the indexed object becomes less than 0 or exceeds the number of objects declared in the configuration In this case it is as if the index were equal to O It must be tested by the user program after each operation where there is a risk of overflow and then reset to O if there is indeed an overflow When the 96820 bit switches to 1 the application stops in error state if the 96878 bit has been set to 1 0 yes no 26821
17. 1RSTTASKRUN first task cycle Tested in a task Mast Fast Aux0 Aux1 Aux2 Aux3 the bit S21 indicates the first cycle of this task S21 is set to 1 at the start of the cycle and reset to zero at the end of the cycle Notes The bit S21 does not have the same meaning in PL7 as in Unity Pro no yes 4 WARNING UNINTENDED EQUIPMENT OPERATION On Quantum Safety PLCs communication interruptions from NOE CRA or CRP modules are not reported on bit 96816 Make certain that these system bits are used correctly Failure to follow these instructions can result in death serious injury or equipment damage 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 137 System Objects Description of the System Bits S30 to S51 Detailed Description NOTE Not all of the system bits can be used in the Quantum Safety PLC The unusable system bits are marked in the Quant Safety column with no The following table gives a description of the system bits S30 to 96851 Bit Function Description Initial Write Quant Symbol State Access Safety S30 activation deacti see chapter System Bits see Unity Pro 1 yes no MASTACT vation of the Program Languages and Structure Reference master task Manual in the Unity Pro Program Languages and Structure Reference Manual 9
18. 20 must be able to deliver the complete power of the drop For details of the configuration of modules see Configuration Examples for the Quantum Safety PLC page 60 52 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 2 4 Non Interfering Modules Non Interfering Modules for the Quantum Safety PLC Introduction The Quantum Safety PLC consists of Safety modules that perform Safety functions This PLC also supports non interfering modules There are 2 groups of non interfering modules e Modules needed to complete a Safety PLC e 140 XBP 006 00 Backplane 6 slots 140 XBP 010 00 Backplane 10 slots 140 XBP 016 00 Backplane 16 slots 140 CRP 932 00 Remote I O Head Adapter 140 CRA 932 00 Remote I O Drop Adapter 140 CPS 124 20 Power Supply e Modules for additional non safety functions 140 NOE 771 11 Ethernet Module 140 DDI 353 00 Digital Input 140 DDO 353 00 Digital Output 140 ACI 040 00 Analog Input e 140 ACO 020 00 Analog Output Additional parts such as cables and terminal strips are also available fora Quantum Safety PLC Description of the RIO Adapters The RIO head adapter 140 CRP 932 00 and the RIO Drop Adapter 140 CRA 932 00 are allowed to be used for the communication between the Safety CPU and the Safety remote I Os For detailed information on this topic see Description of the CPU I O Communication
19. 2010 83 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 3 3 Operating Procedures Introduction This section deals with the operating procedures of the Quantum Safety PLC with special regard to its 2 special operating modes What s in this Section This section contains the following topics Topic Page Operating Modes of the Safety PLC 85 Safety Mode 87 Maintenance Mode 89 Forcing 91 84 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Operating Modes of the Safety PLC Introduction The default behavior of the Quantum Safety PLC is to perform Safety Functions in order to achieve and to maintain the Safe state of a process Nevertheless you must be able to debug and to maintain your project Therefore the Quantum Safety PLC can run in the following 2 operating modes e the Safety Mode e the Maintenance Mode You can use the Safety Mode to control your process whereas the Maintenance Mode is for debugging and tuning your project In Maintenance Mode the I O and CPU modules are still executing the diagnostics and will establish the Safe state if a fault is detected Only the application program and the application data which may be changed in Maintenance Mode are not checked Safety and Maintenance Mode Features The operating mode of the Quantum Safety PLC depends on events s
20. 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Available Language Sections Introduction For programming your SIL3 project you are only allowed to use the following 2 programming languages e function block diagram FBD e ladder diagram LD Both are languages defined by the IEC 61131 3 for the programming of PLCs Description of the Restrictions on Language If you create a SIL3 project the following restrictions apply e Atcreation time Unity Pro XLS restricts your choice of programming language e Atimport time Unity Pro XLS ignores any section other than FBD or LD but does not stop the import The use of sections other than FBD or LD generates errors e Atanalyze time Unity Pro XLS checks each section for its language If any test fails it creates an error and does not generate your program Youcan find a detailed description of the restrictions on program structure language elements and data configuration in Exceptions and Requirements for Programming page 68 33003879 01 2010 67 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Exceptions and Requirements for Programming Introduction To program a SIL3 project you must use the programming languages FBD and LD only while at the same time observing the rules listed below concerning the program structure language elements and data configuration
21. 9123 www barr thorp com 33003879 01 2010 Standalone Safety CPU Introduction For use in standalone SIL3 solutions the 140 CPU 651 60S Quantum Safety CPU is certified The safety CPU includes a PCMCIA memory card see page 19 but its use and presence is not mandatory Description of the Internal CPU Architecture The Quantum Safety CPU contains 2 different processors an Intel Pentium and an application processor Each one executes the Safety logic in its own memory area and both compare the results of the execution at the end of each cycle Two CPUs are available e 140 CPU 651 60S Standalone Safety CPU e 140 CPU 671 60S Hot Standby Safety CPU The following figure shows the internal architecture of the Quantum Safety CPU ops in safe stata in pre cenfic ned fal bark position 33003879 01 2010 33 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Benefits of the Double Code Generation and Execution The 2 processors inside the Quantum Safety PLC allow double code generation and execution This diversity provides the following advantages in error detection e 2 executable codes are generated independently The diversity of compilers allows the detection of systematic error in the code generation e The 2 generated codes are executed by 2 different processors Thus the CPU is able to detect both systematic errors in the code execution and random errors in the
22. DFBs is reserved This bit is read only 96S77 full This bit is set to 1 by the system when the buffer that 0 no yes DIAGBUFFFULL diagnostics receives errors from the diagnostics function blocks is buffer full This bit is read only 969878 stop in the Normally at 0 this bit can be set to 1 by the user to 0 yes yes HALTIFERROR event of program a PLC stop on application fault 96815 96918 error 20 S80 reset Normally set to 0 this bit can be set to 1 by the user to O yes yes RSTMSGCNT message reset the message counters SW80 to SW86 counters S94 saving see chapter System Bits in the Unity Pro Program 0 yes no SAVECURRVAL adjustment Languages and Structure Reference Manual values 968118 General Normally set to 1 this bit is set to 0 by the system when no yes REMIOERR Remote I O a fault occurs on a device connected to the RIO Fipio fault for Premium or Drop S908 for Quantum remote input output bus This bit is reset to 1 by the system when the fault disappears This bit is not updated if an error occurs on the other buses DIO ProfiBus ASI 968119 General Normally set to 1 this bit is set to 0 by the system when no yes LOCIOERR inrack I O a fault occurs on an I O module placed in 1 of the racks fault This bit is reset to 1 by the system when the fault disappears 969120 DIO bus see chapter System Bits in the Unity Pro Program no no 969121 faults Languages and Structure Reference Manual 9608122 140 33
23. Electric Co Inc 800 473 9123 www barr thorp com Word Function Description Initial Write Quant Symbol State Access Safety SW12 mode of This word indicates the operating mode of the 16 A501 no yes APMODE application application processor Possible values are processor e 16 A501 application processor is in Maintenance Mode e 16 5AFE application processor is in Safety Mode Any other value is interpreted as an error This system word is not available for the standard Quantum CPU SW13 mode of Intel This word indicates the operating mode of the Intel 16 501A no yes INTELMODE processor Pentium processor Possible values are e 1635014 application processor is in Maintenance Mode e 16 5AFE application processor is in Safety Mode Any other value is interpreted as an error This system word is not available for the standard Quantum CPU SW14 commercial This word contains the commercial version of the no yes OSCOMMVERS version of PLC processor PLC Example 16 0135 processor version 01 issue number 35 SW15 PLC This word contains the commercial version of the no yes OSCOMMPATCH processor PLC processor patch patch version It is coded onto the least significant byte of the word coding 0 no patch 1 A 2 B Example 16 0003 corresponds to patch C SW16 firmware This word contains the Firmware version number no yes OSINTVERS version in hexadecimal of the PLC processor firmware number Example 16 001
24. Electric Co Inc 800 473 9123 www barr thorp com System Objects B Introduction This chapter describes the system bits and words of the Quantum Safety PLC Note The symbols associated with each bit object or system word mentioned in the descriptive tables of these objects are not implemented as standard in the software but can be entered using the data editor It is suggested that the symbol names associated with the system bits and system words that appear on the following pages be implemented to provide continuity and ease of understanding Example s0 COLDSTART the user can select another word to replace COLDSTART What s in this Chapter This chapter contains the following sections Section Topic Page B 1 System Bits 132 B 2 System Words 141 33003879 01 2010 131 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects B 1 System Bits Introduction This section describes the system bits of the Quantum Safety PLC For your convenience all system bits of standard Quantum PLCs are listed but only explained further if used in the Quantum Safety PLC What s in this Section This section contains the following topics Topic Page System Bit Introduction 133 Description of the System Bits S0 to S13 134 Description of the System Bits S15 to S21 136 Description of the System Bits S30 to S51 138
25. Inc 800 473 9123 www barr thorp com Burner Management Systems In burner management systems the Safe state of the plant is a de energized or low 0 state If a Safety Related System is required to conform with the EN 50156 standard for electrical equipment in furnaces and to conform with the EN 298 standard for automatic gas burner control systems the PLC throughput time should ensure that a Safe shutdown can be performed within 1 second after a problem in the process is detected For the calculation see Process Safety Time page 71 In burner management applications the Safety analog input modules must be monitored for ground faults leakage of current The wires should be connected potential free With a shunt resistor for instance 250 Q between the ground rail of the grounding kit and the earth ground a voltage can be measured in case of a leakage of the current on 1 of the analog inputs This voltage must be supervised to detect a leakage A stabilized power supply of 20 VDC to 25 VDC must be used for the field power 120 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Appendices Introduction The appendices contain information on the IEC 61508 and its SIL policy Further technical data of the Safety and non interfering modules are provided and example calculations are carried out What s in this Appendix The appendix contains the following ch
26. O 33003879 01 2010 35 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Description of the Operating Modes The Hot Standby Safety PLC can run in Safety Mode and in Maintenance Mode e Safety Mode The Safety Mode is the default mode of the Quantum PLC It is a restricted mode in which modifications and maintenance activities are prohibited e Maintenance Mode The Maintenance Mode of the Quantum Safety PLC is a temporary mode for modifying the project debugging and maintaining the application program State Compatibility with Safe and Maintenance Modes e Redundant configuration 1 CPU is primary 1 is standby The Standby CPU controller mode follows the Primary CPU controller mode For example if you switch the Primary CPU controller from Safety to Maintenance mode the Standby CPU controller switches from Safety to Maintenance mode at the start of the next cycle e Non redundant configuration at least 1 CPU offline The two controllers are independent one can be in Safety mode and the other one in Maintenance mode For example the Run Prim controller can be in Safety mode while the Stop OffL controller is in Maintenance mode Impact of the PLC Switch on the Process Safety Time If the primary CPU detects an internal or external problem it stops exchanging data with the Standby CPU and stops processing the I O As soon as the Standby CPU detects that there is no more exchange with th
27. Safety Lifecycle of all components of a Safety Related System used in the process industry 124 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Risk Description The IEC 61508 is based on the concepts of risk analysis and Safety Function The risk depends on severity and probability It can be reduced to a tolerable level by applying a Safety Function that consists of an electrical electronic or programmable electronic system Further it should be reduced to a level that is as low as reasonably practicable In summary the IEC 61508 views risks as follows e Zero risk can never be reached e Safety must be considered from the beginning e Intolerable risks must be reduced 33003879 01 2010 125 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com SIL Policy Introduction The SIL value evaluates the robustness of an application against failures thus indicating the ability of a system to perform a Safety Function within a defined probability The IEC 61508 specifies 4 levels of Safety performance depending on the risk or impacts caused by the process for which the Safety Related System is used The more dangerous the possible impacts are on community and environment the higher the Safety requirements are to lower the risk SIL Value Description Discrete level 1 out of a possible 4 for specifying the Safety Integrity r
28. USB The communication between Unity Pro XLS and the Quantum Safety PLC is not part of the Safety loop but nevertheless subject to checks For instance a CRC is used during the download of a project in order to verify that the data are transferred correctly and that there is no communication error However you must additionally check the version and functionality of your project as well as the Unity Pro XLS environment For the Ethernet cabling the standard Ethernet devices can be used 104 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com PLC PLC Communication Introduction Concerning a Safety PLC only writing to other PLCs is allowed Reading from other PLCs is only allowed in the unrestricted memory area see also Memory Area page 101 NOTE The write access is controlled inside the CPU because some communications for example with the HMI or with other PLCs are not configured in the Safety PLC with Unity Pro XLS and therefore cannot be checked in the configuration The Quantum Safety PLC is able to communicate with other PLCs using the following e Modbus TCP either with CPU or NOE module e Modbus Plus e Modbus RS232 RS485 These kinds of communication are categorized as non interfering NOTE Communication from the Quantum Safety PLC as a Modbus Master via Modbus is not allowed because the function blocks are not certified However as a Modbus slav
29. Word Function Description Initial Write Quant Symbol State Access Safety 96SW80 message These words are updated by the system and can 0 yes yes MSGCNTO management also be reset using S80 e sw80 Number of Modbus messages sent by 9eSW81 the system as client on all communication MSCNT1 ports except USB and Ethernet copro NOTE Modbus messages sent by the system as Master are not counted in this word e Sw8s1 Number of Modbus messages received by the system as client on all communication ports except USB and Ethernet copro NOTE Modbus messages received as response to the requests sent by the system as Master are not counted in this word SW87 communication Number of requests processed by synchronous 0 yes MSTSERVCNT flow server per master MAST task cycle management SW90 maximum This word is used to set a maximum number of 0 yes yes MAXREQNB number of requests which can be processed by the PLC per requests master task cycle processed per When the CPU is the server This number of master task requests must be between 2 minimum and N 4 cycle maximum N number differs depending on the model When the CPU is the client N number differs depending on the model The value 0 does not work If a value that is outside of the range is entered it is the value N that is taken into account See also chapter System Objects in the Unity Pro Program Languages and Structure Reference Manual SW108 number of This system
30. You can also use the Schneider Electric Safety products for creating a hot standby HSBY solution if you require high availability for a Safety Related System 33003879 01 2010 15 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Functional Safety Certification Introduction The Quantum Safety PLC is certified e by T V Rheinland Group e foruse in applications up to and including SIL3 according to IEC 61508 and IEC 62061 This certification verifies that the Quantum Safety PLC is compliant with the following standards e IEC 61508 Functional safety of electrical electronic programmable electronic safety related systems Part 1 7 First edition e IEC 61131 Programmable controllers e Part 2 Equipment requirements and tests Second edition 2003 02 e Boiler protection e European standard EN 50156 e US standards NFPA 85 and NFPA 86 e EN 54 Fire detection and fire alarm systems e EN 298 Automatic gas burner control systems for gas burners and gas burning appliances with or without fans e EC 62061 Safety of machinery e EN ISO 13849 Safety of machinery NOTE Using a Quantum Safety PLC is a necessary but not sufficient precondition for the certification of a SIL3 application A SIL3 application must also fulfill the requirements of the IEC 61508 IEC 61511 IEC 61131 2 and other application standards see also Requirements for Hardware and Programming page 29 Exceptions and Requ
31. as used in Special Message Statement of Consequence We welcome your comments about this document You can reach us by e mail at techcomm schneider electric com This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 33003879 01 2010 General Information on the Quantum Safety PLC Introduction This chapter provides general information on the Quantum Safety PLC What s in this Chapter This chapter contains the following sections Section Topic Page 1 1 General Information 14 1 2 Safety Requirements 29 33003879 01 2010 13 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 1 1 General Information Introduction This section provides information on the Quantum Safety PLC What s in this Section This section contains the following topics Topic Page IEC 61508 and Safety Integrity Level SIL 15 Functional Safety Certification 16 Special Operating Modes 23 Diagnostics 24 Difference Between Standard Quantum PLC and Quantum Safety PLC 25 Training 28 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 33003879 01 2010 IEC 61508 and Safety Integrity Level SIL Introduction The Quantum Safety PLC is a Safety Related System certified according to IEC 61508 by TUV Rheinland Group It is based on the Quantum family of programmab
32. for Configuring Data You are only allowed to use e the elementary data types EDTs BOOL EBOOL BYTE WORD DWORD INT UINT DINT UDINT FLOAT and TIME e simple arrays the index can only be a literal but for Ethernet global data communication only for details see the chapter Programming in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics e direct addressing for instance writing MW4000 by a coil in LD e located variables All instances of variables are not only checked with regard to being located but also as to being located in a valid memory area see also Memory Area page 101 You are not allowed to create derived data types DDTs NOTE You are not allowed to use variables from the unrestricted memory areas in your user logic unless you may connect it to the input of S_SMOVE_BIT or S SMOVE WORD function blocks see also Memory Area page 101 Checks for Programming At creation time of a SIL3 project Unity Pro XLS offers only the features allowed for Safety logic Any attempt to create objects not allowed leads to an error However objects not allowed can be inserted through source file import Therefore Unity Pro XLS checks all objects at analyze time At any rule not obeyed or any object not allowed Unity Pro XLS creates an error and does not generate your project In the project settings Unity Pro XLS provides the following different opti
33. of the system such as power supplies sensors and other input devices data highways and other communication paths and actuators and other output devices PES is another term for a computer control system or PLC 162 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary PFD PFH PLC project proof test proof test interval probability of failure on demand Definition IEC 61508 For a single channel system the average probability of a failure on demand is calculated as follows PFD gy 5 putt For a dual channel system the average probability of a failure on demand is calculated as follows PFD a pucm puem r cc For a dual channel system also the Common Cause effect CC must be considered The common cause effect ranges from 1 to 10 of PFDcy and PFDcuo 1 RRF probability of failure per hour Definition IEC 61508 programmable logic controller A project is a user application in Unity Pro XLS periodic test performed to detect failures in a safety related system so that if necessary the system can be restored to an as new condition or as close as practical to this condition Definition IEC 61508 The proof test interval is the time period between proof tests 33003879 01 2010 163 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary PRT PLC reaction time
34. the ground of the actuators For further details see the Quantum with Unity Pro Discrete and Analog I O Reference Manual NOTE It is recommended connecting at least 2 ground lines common OV to the terminal block Description of the Diagnostics To check if both switches can open and close a pulse test is performed on the output modules in the module s internal circuitry diagnostic cycles are inserted periodically The diagnostic sequence is as follows Stage Description 1 The switch command is modified for a time short enough to not affect actuators which is a maximum of 1 ms If the actuator is sensitive to this 1 ms using 2 outputs of the same output module in parallel can avoid a disturbance 2 The result is verified and the correct switch command is restored Description of the Power Supply Supervision Each output circuit is composed of 2 switches in series controlled separately by the 2 processors The first micro processor uses a DOD to drive its switch whereas the second one drives its switch after de serialization In both micro processor systems the midpoint voltage is compared to 1 threshold Both systems exchange their results evaluate the midpoint state and diagnose the status of the switches at each cycle If a fault in 1 of the channels is detected it is shut down which is signaled to the CPU by setting a diagnostic bit 50 33003879 01 2010 This document provided by Barr Thorp
35. the real time clock is missing or that its system words SW50 to SW53 are meaningless If setto 1 the clock must be resetto the correct time 138 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Description of the System Bits S59 to S122 Detailed Description NOTE Not all of the system bits can be used in the Quantum Safety PLC The unusable system bits are marked in the Quant Safety column with no The following table gives a description of the system bits 96859 to 968122 Bit Function Description Initial Write Quant Symbol State Access Safety S59 incremental Normally set to O this bit can be set to 1 or O by the 0 yes yes RTCTUNING update of program or the terminal the time setto 0 the system does not manage the system and date word SW59 via word setto 1 the system manages edges on word SW59 SW59 to adjust the date and current time by increment S67 state of the This bit is used to monitor the status of the main battery no yes PCMCIABATO application when the memory card is in the upper PCMCIA slot all memory the Atriums Premiums and on the Quantums card battery e set to 1 main voltage battery is low application is preserved but you must replace the battery following the so called predictive maintenance procedure set to 0 main battery voltage is sufficient
36. the wiring must be done accordingly Connect the unused input channels of the used input modules to 24 VDC This is required to avoid creating open circuit faults due to the Safety digital input module s open circuit detection of these unused inputs 33003879 01 2010 47 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Description of the Diagnostics Each input channel uses a common input circuit and 2 independent acquisition chains Each micro processor drives a digital input serializer DIS which samples the input information Further it drives a digital input deserializer DID on each input circuit which in turn drives the diagnostic block in order to set diagnostic cases The acquisitions are synchronous to be comparable Description of the Input Channel Error Detection The digital input monitors the field side power supply The external wiring is checked by sensing the leakage current The minimum leakage current is 1mA If there is no leakage current this is detected as an open circuit In case of dry contact a pull up resistor of 15 kO is needed to avoid broken wire detection Each input circuit is equipped with switches which are periodically forced to 1 or to open circuit state in order to check if the circuit is healthy Each input circuit is checked independently and declared unhealthy in case of a fault by setting a diagnostic bit 48 33003879 01 2010 This document pro
37. type size to connect the inputs outputs of the I O modules with the sensors and actuators RIO adapter see page 53 For unused inputs of the Safety analog input module the health bit of unused inputs should be masked in the health word of the module in your application logic wiring of SAI see page 45 O oO OF OF LI D DEDI CI 114 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 33003879 01 2010 Checks Reference in this Done Remarks Manual Check that sensors and actuators connected process safety time to the I O modules respect the specified see page 71 O values and limits of the I O modules Use the red labels for the terminal blocks gen inf on safety provided with the Safety I O modules to I Os see page 39 O indicate clearly the Safety modules 33003879 01 2010 115 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Checklist for Operation Maintenance and Repair Introduction This list is not exhaustive and you are fully responsible for observing all Safety requirements mentioned in the IEC 61508 as well as in this manual Checklist Schneider Electric recommends that you use the following checklist for operation maintenance and repair of your Safety Related System Checks Reference in Done Remarks this Manual Define a standard operating procedure SO
38. 003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects B 2 System Words Introduction This section describes the system words of the Quantum Safety PLC For your convenience all system words of standard Quantum PLCs are listed but only explained further if used in the Quantum Safety PLC What s in this Section This section contains the following topics Topic Page Description of the System Words SW0 to SW21 142 Description of the System Words SW30 to SW59 145 Description of the System Words SW60 to SW127 148 33003879 01 2010 141 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Description of the System Words SW0 to SW21 Detailed Description NOTE Not all of the system words can be used in the Quantum Safety PLC The unusable system words are marked in the Quant Safety column with no The following table gives a description of the system words SWO to SW21 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Word Function Description Initial Write Quant Symbol State Access Safety SWO0 master task see chapter System Objects see Unity Pro 0 yes no MASTPERIOD scanning Program Languages and Structure Reference period Manual in the Unity Pro Pro
39. 123 www barr thorp com Forcing Introduction Forcing is only possible in Maintenance Mode However it is possible to switch from Maintenance Mode to Safety Mode while data are forced and the forcing stays active NOTE Check the latest version of the T V document Maintenance Override for the procedures which must be applied when using forcing in a Safety Related System You can find it on the T V Rheinland Group website http www tuvasi com A WARNING LOSS OF ABILITY TO PERFORM SAFETY FUNCTIONS Make sure that the forcing is turned on only temporarily and that the user logic is supervising the status of forcing SW108 see Description of the System Words SWEO to SW127 page 148 Failure to follow these instructions can result in death serious injury or equipment damage 33003879 01 2010 91 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Handling Forced Data Because forced data stays forced Unity Pro XLS warns you before executing your switch command from Maintenance Mode to Safety Mode and prompts you to confirm it NOTE In case of a disconnection between PLC and Unity Pro XLS the latter also warns you if there are forced data independently of the mode the PLC is in This is due to the fact that the PLC automatically enters Safety Mode when being disconnected from Unity Pro XLS by the user or a communication interruption A WARNING RISK OF P
40. 140 SAI 940 00S 8 932E 06 1 428E 09 Power Supply PS 140 CPS 124 20 Product Type Product Reference PTI 15 years PFDg PFHg Standalone Safety 140 CPU 651 60S 1 439E 04 6 089E 09 CPU Hot Standby Safety 140 CPU 671 60S 1 439E 04 6 089E 09 CPU Digital Input 140 SDI 953 00S 8 415E 06 1 875E 09 Digital Output 140 SDO 953 00S 1 073E 05 1 204E 09 Analog Input 140 SAI 940 00S 1 340E 05 1 430E 09 Power Supply PS 140 CPS 124 20 Product Type Product Reference PTI 20 years PFDg PFHg Standalone Safety 140 CPU 651 60S 2 003E 04 6 577 E 09 CPU Hot Standby Safety 140 CPU 671 60S 2 003E 04 6 577E 09 CPU Digital Input 140 SDI 953 00S 1 122E 05 1 878E 09 Digital Output 140 SDO 953 00S 1 431E 05 1 206E 09 Analog Input 140 SAI 940 00S 1 786E 05 1 432E 09 Power Supply PS 140 CPS 124 20 The Quantum Safety PLC is programmed with Unity Pro XLS CPU and IO detect the power supply errors therefore the power supply does not contribute to the PFD PFH values 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com PCMCIA Memory Cards The values in the Safety module tables above include the use of the following PCMCIA memory cards TSX MCPC 002M TSX MRPC 768K TSX MCPC 512K TSX MRPC 001M TSX MFPP 001M TSX MRPC 01M7 TSX MFPP 002M TSX MRPC 002M TSX MFPP 004M TSX MRPC 003M TSX MFPP 512K TSX MRPC 007M
41. 25 is only reset after init or complete download or restart it always contains the last fault detected no yes 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 153 System Objects Word Function Description Initial Write Quant Symbol State Access Safety SW126 blocking fault Address of the instruction that generated the 0 no yes ERRADDRO instruction application blocking fault SW127 address For 16 bit processors ERRADDR1 e SW126 contains the offset for this address e SW127 contains the segment number for this address For 32 bit processors e SW126 contains the least significant word for this address e SW127 contains the most significant word for this address The content of SW126 and SW127 is for Schneider Electric use only For the description of the system words SW128 to S8W339 and SW535 to SW640 see the chapter Quantum Specific System Words in the Unity Pro Program Languages and Structure Reference Manual The system words SW340 to SW534 are not used in Quantum Safety PLCs 154 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary 0 9 NOTE For terms taken from the IEC 61508 standard refer to the standard for complete definitions 1002D diagnostic configuration X out of Y For example 1 out of 2 Voting an
42. 33003879 03 Modicon Quantum Quantum Safety PLC Safety Reference Manual 01 2010 www schneider electric com Schneider Electric This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com The information provided in this documentation contains general descriptions and or technical characteristics of the performance of the products contained herein This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications It is the duty of any such user or integrator to perform the appropriate and complete risk analysis evaluation and testing of the products with respect to the relevant specific application or use thereof Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein If you have any suggestions for improvements or amendments or have found errors in this publication please notify us No part of this document may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission of Schneider Electric All pertinent state regional and local safety regulations must be observed when installing and using this product For reasons of safety and to help ensure compliance with documented system data only the manufacturer should perform repairs to compon
43. 61131 2 Programmable controllers Part 2 Equipment requirements and tests Second edition 2003 02 IEC 61508 Functional safety of electrical electronic programmable electronic safety related systems First edition IEC 61511 Functional safety safety instrumented systems for the process industry sector First edition You can download these technical publications and other technical information from our website at www schneider electric com 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Product Related Information Schneider Electric assumes no responsibility for any errors that may appear in this documentation Please contact us if you have any suggestions for improvements or amendments or if you have found any errors in this publication No part of this documentation may be reproduced in any form or by any means electronic or mechanical including photocopying without written permission of Schneider Electric All pertinent state regional and local safety regulations must be observed when installing and using this product For reasons of safety and to ensure compliance with documented system data only the manufacturer should perform repairs to components When controllers are used for applications with technical safety requirements please follow the relevant instructions 4 WARNING UNINTENDED EQUIPMENT OPERATION Use only Schneider Elec
44. 6831 activation deacti see chapter System Bits see Unity Pro 0 yes no FASTACT vation of the fast Program Languages and Structure Reference task Manual in the Unity Pro Program Languages and Structure Reference Manual 96832 activation deacti see chapter System Bits see Unity Pro 0 yes no S33 vation of the Program Languages and Structure Reference S34 auxiliary tasks Manual in the Unity Pro Program Languages and S35 0 3 Structure Reference Manual S38 enabling inhibiti see chapter System Bits see Unity Pro 1 yes no ACTIVEVT on of events Program Languages and Structure Reference Manual in the Unity Pro Program Languages and Structure Reference Manual S39 saturation in see chapter System Bits see Unity Pro 0 yes no EVTOVR event Program Languages and Structure Reference processing Manual in the Unity Pro Program Languages and Structure Reference Manual S50 updating of time Normally set to 0 this bit is set to 1 by the program 0 yes yes RTCWRITE and date via or the terminal words SW50 e set to 0 update of system words SW50 to to SW53 SW53 by the date and time supplied by the PLC real time clock setto 1 system words SW50 to SW53 are no longer updated therefore making it possible to modify them e The switch from 1 to O updates the real time clock with the values entered in words SW50 to SW53 96851 time loss in real This system managed bit set to 1 indicates that no yes RTCERR time clock
45. 7 version 2 1 VN 17 SW17 error status see chapter System Objects see Unity Pro 0 yes yes FLOATSTAT on floating Program Languages and Structure Reference operation Manual in the Unity Pro Program Languages and Structure Reference Manual SW17 1 Flag not managed by Quantum Safety 33003879 01 2010 143 System Objects Word Function Description Initial Write Quant Symbol State Access Safety SW18 absolute time SW18 is the low and SW19 the high word for O yes yes SW19 counter calculating durations Both are incremented every 100MSCOUNTER 1 10th of a second by the system even when the PLC is in STOP they are no longer incremented if it is powered down They can be read and written by the user program or by the terminal SW20 absolute time The low word SW20 and the high word SW21 0 no yes SW21 counter are incremented every 1 1000th of a second by MSCOUNTER the system even when the PLC is in STOP they are no longer incremented if it is powered down They can be read by the user program or by the terminal SW20 and SW21 are reset on a cold start but not on a warm start 144 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Description of the System Words SW30 to SW59 Detailed Description NOTE Not all of the system words can be used in the Quantum Safety PLC The unusable sy
46. Animation tables and operator screens can write Safety variables and Safety I Os e The Safety memory is write protected that means that HMIs or other PLCs cannot write to it This is controlled by the Safety PLC see also Memory Area page 107 Entering Maintenance Mode You can only enter Maintenance Mode from Safety Mode because after power up the PLC automatically enters Safety Mode To exit Safety Mode and enter Maintenance Mode the key switch must be unlocked You can find procedures for switching between the modes in the chapter Switching Between Safety and Maintenance Mode in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics 33003879 01 2010 89 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Maintenance Mode States In Maintenance Mode the PLC can be in run state or in halt state When it is in run state you can modify your project Further you can switch to Debug Mode if you want to debug and maintain your program In run state the double code execution is performed but the result of the comparison is ignored 4 DANGER RISK OF LOSING THE SAFETY FUNCTION DURING COMMISSIONING AND MAINTENANCE All modifications of the running system must follow the requirements of the IEC 61508 Failure to follow these instructions will result in death or serious injury 90 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9
47. C sequential function chart This is an IEC 61131 3 programming language for PLC user logic SFF safe failure fraction SFR Safety Functional requirement Safety Functional requirements are derived from the hazard analysis and define what the function does for instance the Safety Function to be performed 33003879 01 2010 167 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary SIL NOTE For complete definitions and parameters related to SIL ratings refer to IEC 61508 Functional safety of electrical electronic programmable electronic safety related systems Provided here is a partial definition safety integrity level discrete level 1 out of a possible 4 for specifying the safety integrity requirements of the safety functions to be allocated to the E E PE safety related systems where safety integrity level 4 has the highest level of safety integrity and safety integrity level 1 has the lowest Definition IEC 61508 SIL2 project application A project application that uses a Quantum Safety PLC 140 CPU 651 60S V1 00 or 140 CPU 671 60S V1 00 to implement Safety Functions in a Safety Related System SIL3 project application A project application that uses a Quantum Safety PLC 140 CPU 651 60S V2 00 or 140 CPU 671 60S V2 00 to implement Safety Functions in a Safety Related System SIR Safety Integrity requirement Safety Integrity requirements are derived from a risk ass
48. Co Inc 800 473 9123 www barr thorp com Glossary HSBY IEC IEC 61508 LCD LD MTBF MTTF Hot Standby International Electrotechnical Commission The IEC 61508 standard is an international standard that addresses Functional Safety of electrical electronic programmable electronic Safety Related Systems It applies to any kind of Safety Related System in any industry wherever there are no product standards instruction list This is an IEC 61131 3 programming language for PLC user logic L liquid crystal display ladder diagram This is an IEC 61131 3 programming language for PLC user logic mean time between failures mean time to failure 33003879 01 2010 161 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary MTTR NFPA mean time to repair N National Fire Protection Association This is a body for establishing codes and standards for fire protection electrical and machine Safety in the U S non interfering module PELV PES Non interfering modules are modules that are not directly used to control the Safety Function They do not interfere with the Safety modules either during normal operation or if there is a fault P protected extra low voltage programmable electronic system Definition IEC 61508 System for control protection or monitoring based on 1 or more programmable electronic devices including elements
49. Description of the System Bits 76559 to S122 139 132 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 33003879 01 2010 System Objects System Bit Introduction General The Quantum PLCs use Si system bits which indicate the state of the PLC or they can be used to control how it operates These bits can be tested in the user program to detect any functional development Some of these bits must be reset to their initial or normal state by either the program or the user Other bits are automatically reset by the system Finally there are bits which only display the status of the PLC 33003879 01 2010 133 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Description of the System Bits S0 to 96813 Detailed Description NOTE Not all of the system bits can be used in the Quantum Safety PLC The unusable system bits are marked in the Quant Safety column with no The following table gives a description of the system bits S0 to S13 Bit Function Description Initial Write Quant Symbol State Access Safety 9eS0 cold start Normally at 0 this bit is set to 1 by 1 no yes COLDSTART e power restoration with loss of data battery related 1 e the user program cycle e the terminal e achange of cartridge This bit is set to 1 during the first complete restored cycle of the PLC either in RUN or i
50. Electric Co Inc 800 473 9123 www barr thorp com Description of the Time out State You can configure a time out state for your Safety Related output modules for the following cases e the detection of a malfunction of the CPU e the occurrence of a communication problem You can configure the following 3 time out states e hold last value e user defined 0 which is the Safe state e user defined 1 You can find a detailed procedure for configuring the time out state and the module time out of digital output modules in the chapter Configuring I O Modules for Safety Projects in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics A WARNING POSSIBLE LOSS OF THE ABILITY TO ENTER SAFE STATE Configure a time out state of O for your Safety digital output modules The Quantum Safety PLC can only guarantee that the outputs go to Safe state which equals 0 or the de energized state A time out state of 1 is configurable but cannot be guaranteed Failure to follow these instructions can result in death serious injury or equipment damage 4 WARNING RISK OF UNPERCEIVED BEHAVIOR Keep in mind that the output goes to de energized state independent of the value defined for the time out state in case the module detects an internal fault Failure to follow these instructions can result in death serious injury or equipment damage Description of the Module Time out The module time out must be con
51. FH of PFH PLC 15 of PFH of Safety bop For the calculation of the PFD PFH values of an example system a maximum of 15 is assumed for the PLC For the PFD PFH values of the Quantum Safety modules see Available Safety Products page 17 NOTE The programming tool Unity Pro XLS is not part of the Safety loop For detailed information on the IEC 61508 and its SIL policy see also chapter IEC 61508 page 123 Example Calculation The following table gives 2 example calculations for PFD values within a SIL3 Safety loop with an assumed proof test interval of 10 years If the Safety loop contains Then the PLC contributes to And sensors and the Safety loop with actuators can use e 1 digital input 2 11 2 15 85 e 1 digital output and e astandalone CPU e 2 sensors 2 11 2 15 85 e 2 redundant analog inputs Note All doubled modules e 2redundant digital outputs and contribute only once because e 2 Hot Standby CPUs the redundancy is only for high availability Thus only 1 module is active in the Safety loop Safety Times Description The Quantum Safety PLC has a minimum PLC cycle time of 20 ms which is necessary for processing the signals from the I O modules executing the user logic and setting the outputs For calculating the maximum PLC reaction time the maximum reaction time of the sensors and actuators you use must be known Further the maximum PLC reaction time depends on the process S
52. Inc 800 473 9123 www barr thorp com Glossary FMEA FMECA Functional Safety HALT HFT HMI failure modes and effects analysis failure modes and effects criticality analysis part of the overall safety relating to the EUC and the EUC control system which depends on the correct functioning of the E E PE safety related systems other technology safety related systems and external risk reduction facilities Definition IEC 61508 A system is defined functionally Safe if random systematic and common cause failures do not lead to malfunctioning of the system and do not result in injury or death of humans spills to the environment and loss of equipment or production e Functional Safety deals with the part of the overall Safety that depends on the correct functioning of the Safety Related System e Functional Safety applies to products as well as organizations H high accelerated life tests hardware fault tolerance Definition IEC 61508 A hardware fault tolerance of N means that N 1 faults could cause a loss of the Safety Function for instance e HFT 0 The 1st failure could cause a loss of the Safety Function e HFT 1 2faults in combination could cause a loss of the Safety Function There are 2 different paths to go to a Safe state Loss of the Safety Function means that a Safe state cannot be entered human machine interface 160 33003879 01 2010 This document provided by Barr Thorp Electric
53. JoSW33 145 JoS50 138 o 5 JoSW34 145 JoS51 138 SW35 145 96859 139 E i 33003879 01 2010 173 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Index SW36 to SW47 145 SW4 142 SW48 145 SWA4Y 146 SW5 142 SW50 146 SW51 146 SW52 146 SW53 146 SW54 147 SW55 147 SW56 147 SW57 147 SW58 147 SW59 147 SW8 142 SW81 151 SW9 142 0 9 100MSCOUNTER 144 1RSTSCANRUN 135 1RSTTASKRUN 137 61508 IEC 124 61511 IEC 124 A ACTIVEVT 138 ADJDATETIME 147 APMODE 143 application password 83 loss of 83 auto lock 78 Automatic start in Run 88 95 automatic swap 27 BLKERRTYPE 153 C CARRY 136 checklist for configuring Safety Related Systems 110 for I O modules 114 for operation maintenance and repair 116 for programming SIL3 applications 112 cold start 25 95 COLDSTART 134 CPUERR 152 CRC cyclic redundancy check 34 94 cyclic redundancy check CRC 34 94 D DAYOFWEEK 146 DIAGBUFFCONF 140 DIAGBUFFFULL 740 diagnostics 24 DLASTDEREG 150 DLASTREG 150 DLL dynamic link library 94 DNBERRBUF 150 double code execution 34 double code generation 34 dynamic link library DLL 94 E ERRADDRi 154 EVTOVR 138 F failure rate 130 FASTACT 138 FASTPERIOD 142 firmware 20 22 FLOATSTAT 143 FORCEDIOIM 751 forcing 87 89 174 33003879 01 2010 This document provided by Barr Thorp Elect
54. Keypad yes yes application mismatch yes no OS Upgrade yes if Standby is in Stop Offline no Application Transfer yes no For details of how to configure and operate Quantum Hot Standby systems see the Modicon Quantum Hot Standby with Unity User Manual 33003879 01 2010 37 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 2 2 Safety I O Modules Introduction This section deals with the 3 Safety I O modules developed for use in the Quantum Safety PLC The features that the 3 modules share are described in general whereas their distinctions are explained separately What s in this Section This section contains the following topics Topic Page General Information on the Safety I O Modules 39 Safety I O Modules in High Availability Configurations 40 Safety I O Modules Diagnostics 43 Safety Analog Input Module 45 Safety Digital Input Module 47 Safety Digital Output Module 49 38 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 33003879 01 2010 General Information on the Safety I O Modules Introduction The following 3 Quantum Safety I O modules are certified for use in safety applications e 140 SAI 940 00S Analog Input e 140 SDI 953 00S Digital Input e 140 SDO 953 008 Digital Output The 3 Safety I O modules allow you to connect the Safety PLC to the sensors and actuat
55. P for operation maintenance and repair of the Safety instrumented system and O ensure that it is respected Define a maintenance plan for your Safety Related System Proof Test according to the proof test interval Interval page 22 Maintain your Safety Related System according to your maintenance plan Create backups of your SIL3 project on a regular basis Project Backups page 98 When changing the Safety Related System follow the rules of the IEC61508 1 chapters 7 15 and 7 16 even if only non Safety Related parts are modified Follow the guidelines of the Maintenance Override T V document Forcing when using forcing available on http www tuvasi com page 91 Check that forcing is switched off after the maintenance operation Forcing either as part of the application or by an appropriate standard page 91 operating procedure Monitor the status of the Safety I O modules health out of range Description of overload invalid channel see also the Quantum with Unity Pro the RIO Discrete and Analog I O Reference Manual Adapters page 53 Description of the CPU I O Communication page 39 O O O OF DIEI OU 116 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Checks Reference in this Manual Done Remarks In a redundant I O system signal a fault in 1 of the redundant modules to the ma
56. PLC e 2independent memory areas are used for the 2 processors Thus the CPUs are able to detect random errors in the RAM and a full RAM test is not necessary at every scan Description of the Watchdog A hardware and a firmware watchdog check the PLC activity and the time needed to execute the user logic NOTE You must configure the software watchdog maximum PLC cycle time to be consistent with the application execution time the filtering of the I O communication error and the process Safety time PST targeted see also Process Safety Time page 71 Description of the Memory Check Static memory areas including the Flash memory PCMCIA memory card see page 19 if any and the RAM are checked using the cyclic redundancy check CRC and the double code execution Dynamic areas are protected by the double code execution and a periodic memory test At cold start these tests are re initialized and fully performed before the CPU goes into Stop or Run mode 34 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Hot Standby Safety CPU Specifics Introduction The 140 CPU 671 60S Quantum Safety CPU module is certified for use in Hot Standby SIL3 solutions compliant to 61508 IEC standard For more details according to the safety certifications see the Quantum Safety PLC see page 13 In a Hot Standby configuration 1 CPU is the Primary CPU and the other is the Stan
57. ROCESSING FORCED DATA Check the state of your data before switching from Maintenance Mode to Safety Mode Forced data stays forced and the PLC continues processing them Make sure that your PLC processes the correct unforced data necessary for performing the Safety Functions Failure to follow these instructions can result in death serious injury or equipment damage You can check the status of forcing by reading the system word SW108 It contains the number of forced I O module bits The system word is incremented on every forcing and decremented on every unforcing 92 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 3 4 Special Features and Procedures Introduction This section explains the special features and procedures using Unity Pro XLS as a programming tool for SIL3 projects What s in this Section This section contains the following topics Topic Page Checking the Programming Environment 94 Starting the Quantum Safety PLC 95 Version Stamp 96 Upload 97 Project Backups 98 Detected Faults 99 33003879 01 2010 93 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Checking the Programming Environment Introduction Unity Pro XLS provides the possibility to perform a self test in order to verify that the components currently in use are the correct version
58. SW60 e SW60 0 1 invalidates the commands entered in the display keypad e ssw60 1 e 0 sets PLC A to OFFLINE mode 1 sets PLC A to RUN mode e 5W60 2 e 0 sets PLC B to OFFLINE mode 1 sets PLC B to RUN mode e SW60 3 0 forces Standby PLC to OFFLINE mode if the applications are different e 5W60 4 e 0 authorizes an update of the firmware only after the application has stopped e 1 authorizes an update of the firmware without the application stopping e SW60 5 1 application transfer request from the Standby to the primary 5W60 8 e 0 address switch on Modbus port 1 during a primary swap e 1 no address switch on Modbus port 1 during a primary swap 0 no yes 148 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 33003879 01 2010 System Objects Word Symbol Write Access Quant Safety Initial State Function Description SW61 HSB_STS Quantum status register Meaning of the different bits of the word sw61 O no e Sw61 0und Sw61 1 PLC operating mode bits e sSw61 1 0 Sw61 0 1 OFFLINE mode e SW61 1 1 SW61 0 0 primary mode SW61 1 1 3SW61 0 1 secondary mode Standby SwW61 2 and SW61 3 operating mode bits from the other PLC yes SW61 320 SW61 mode SW61 321 SW61 SW61 3 21 SW61 mode Standby SW61 320 SW61 221 OFFLINE 220 primary mode 2 1 secondary
59. Safety Mode NOTE After power up and if there is a valid application the PLC only performs cold start Thus the project is reinitialized and the system performs the initialization of data with the initial values defined in the project the initialization of elementary function blocks EFBs based on initial data the initialization of data declared in the EFBs the initialization of system bit and words e the cancellation of any forcing see also Forcing page 91 Switching from Maintenance Mode to Safety Mode is only possible if the PLC is not debugging NOTE Data forced before switching to Safety Mode stay forced after switching see also Forcing page 91 Details concerning the transition from Maintenance Mode to Safety Mode can be found in the chapter Switching Between Safety and Maintenance Mode in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics Automatic Start in Run Option You have the possibility to let your project automatically enter Safety Mode s run state after power up To do this activate the option Automatic start in Run see also the chapter Configuration of Quantum Processors see Unity Pro Operating Modes in the Unity Pro Operating Modes Manual However Schneider Electric recommends using the Run command instead of the Automatic start in Run option for a SIL3 project to enter run state A WARNING UNINTENDED EQUIPMENT OPERATION Avoid using the Automatic start in Run option If you
60. This is controlled by the Safety PLC see also Memory Area page 101 NOTE The logic animation animation tables and operator screens can influence the scan time NOTE It is possible to download a new version of the Ethernet processor firmware into the Quantum Safety CPU with the OSLoader However it is only allowed to do that in Maintenance Mode 4 WARNING POSSIBLE LOSS OF THE ABILITY TO PERFORM SAFETY FUNCTIONS Do not download a new version of the Ethernet processor firmware into the Quantum Safety CPU in Safety Mode It is possible to do so but not allowed Failure to follow these instructions can result in death serious injury or equipment damage Safety Mode States Once the Safety Mode is entered the PLC can be in run state and in error state In run state all restrictions are active and the results of the double user code execution are compared If any test is unsuccessful the PLC goes to error state because it has no means to recover from the error 33003879 01 2010 87 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Entering Safety Mode There are 4 ways of entering Safety Mode e when the Safety PLC is powered up e when the Safety Mode is entered from Maintenance Mode e when the key is locked e when Unity Pro XLS is disconnected either by the customer or because of a broken connection When the Safety PLC is powered up it automatically enters
61. Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary VDE Verband Deutscher Elektroingenieure This is the German equivalent of the IEEE warm start Warm start refers to restarting the computer without turning the power off 170 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary 33003879 01 2010 171 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary 172 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Index Symbols S6 134 S0 134 S67 139 96968 139 JoS1 134 M JoS7 134 S10 135 M 96975 139 S11 135 o 2 JoS76 140 709118 140 6 JoS77 140 709119 140 n o S78 140 70912 135 o S80 140 7098120 140 M JoS94 140 709121 140 o H JoSWO 142 7098122 140 M JoSW1 142 76913 135 5 JoSW10 142 S15 136 JoSW11 142 76916 136 JoSW12 143 JoS17 136 JoSW13 143 76918 136 M JoSW14 143 S19 136 M 4 SW15 143 S20 137 5 M JoSW 16 143 JoS21 137 S JoSW17 143 JoS30 138 o SW18 144 JoS31 138 6 M JoSW19 144 JoS32 138 3 H JoSW2 142 JoS33 138 o M JoSW20 144 JoS34 138 9 JoSW241 144 S35 138 K o JoSW3 142 Jo938 138 o 5 JoSW3230 145 S39 138 o JoSW31 145 JoS4 134 o JoSW32 145 JoS5 134 o E
62. Validity Note This documentation is valid for Unity Pro from version 5 0 33003879 01 2010 9 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Related Documents You can download the Schneider Electric technical publications and other technical information from our website NOTE All restrictions regarding electrical safety and external cabling and wiring must follow the documents in this table and the contents of this manual Title of Documentation Reference Number Modicon Quantum with Unity Ethernet Network Modules User Manual 33002479 Grounding and Electromagnetic Compatibility of PLC Systems User 33002439 Manual Modicon Quantum Hot Standby with Unity User Manual 35010533 Modicon Remote I O Cable System Planning and Installation Guide 043507263 Premium Atrium and Quantum using Unity Pro Communication 35006173 services and architectures Reference manual Quantum Instruction Sheets 33002365 Quantum TCPIP IP Configuration User Manual 33002467 Quantum with Unity Pro Discrete and Analog I O Reference Manual 35010516 Quantum with Unity Pro Hardware Reference Manual 35010529 Unity Pro Operating Modes Manual 33003101 Unity Pro OSLoader User Manual 35006156 Unity Pro Program Languages and Structure Reference Manual 35006144 Unity Pro Safety Block Library 33003873 Unity Pro XLS Operating Mode Manual Safety PLC Specifics 33003885 IEC
63. afety time PST required for your process You can find details of how to configure your PLC reaction time in Process Safety Time page 71 33003879 01 2010 21 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Proof Test Interval Certified Products The proof test is a periodic test performed to detect failures in a Safety Related System so that if necessary the system can be restored to a like new condition or as close as practical to this condition The time period between these tests is the proof test interval The proof test interval depends on the targeted Safety Integrity Level the sensors actuators and the PLC application The Quantum is suitable for use in a SIL3 application and a proof test interval of 10 years See Available Safety Products and Proof Test procedure see page 17 The Safety product versions are certified Only certified versions are allowed for programming commissioning and operating the Quantum Safety PLC NOTE Only Safety firmware can be loaded into the Quantum Safety PLC The Safety firmware is loaded with the OSLoader into the Quantum Safety PLC Further information on how to load the firmware can be found in the Unity Pro OSLoader User Manual A WARNING Degrading the Safety Integrity Level Only a CPU with Firmware Version 2 0 and above is suitable for SIL3 A CPU with Firmware Version 1 0 is only suitable for SIL2 applications Failure to
64. alculate the maximum PLC reaction time tolerable in your process To ensure that the system reaction time is smaller than the process Safety time the maximum CPU cycle time must fulfill the following condition Max CPU cycle time PST Ti z To s Ts Ta 2 Ncnc In addition you must consider the following relation between the maximum timeout Tou1 for the output modules and the maximum CPU cycle time TouT max CPU cycle time x 1 t Ncnc Example Calculation The following values are given required PST 1 1 s T 45 ms To 15 ms Ts 100 ms TA 500 ms Ncrc 1 The maximum CPU cycle time is calculated as follows Max CPU cycle time lt 1100 ms 45 ms 15 ms 100 ms 500 ms 3 Max CPU cycle time lt 146 7 ms The requirement that the module timeout of the digital output module must be greater than the CPU cycle time is fulfilled Tout gt 300 ms In case of a fault of the CPU the outputs are set to Safe state after the timeout has expired Therefore the system needs the following time to shut down the outputs Tout To In the example this time amounts to 300 ms 15 ms 315 ms 33003879 01 2010 73 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com CPU Cycle Time in a Hot Standby System In a normally running Hot Standby system the formula for the CPU cycle time is the same Max CPU cycle time PST Ti To Ts Ta 2 Ncnc In addition yo
65. amp Version Stamp Description In Unity Pro XLS each generated binary file of a SIL3 project has a version stamp providing date and time of build Thus you can check both if and when your project has been subject to modifications You can find a detailed procedure for checking the project version in the chapter Project Properties for Unity Pro XLS in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics 96 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Upload Uploading a SIL3 Project Uploading a project from the PLC to Unity Pro XLS is also available for SIL3 projects If you want to use this feature it must be selected in the project settings In a SIL3 project the application password must be known to be able to connect to the PLC In addition the PLC must be switched to Maintenance Mode to perform the upload For further details see the chapter Project Settings see Unity Pro Operating Modes in the Unity Pro Operating Modes Manual 33003879 01 2010 97 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Project Backups Introduction Unity Pro XLS checks the integrity of your SIL3 project by calculating a CRC when you close it and checking the CRC when you open it again The CRC indicates by changing its value if your project has been damaged or corrupted In this case the comparison indicates t
66. application is preserved Bit S67 is managed e onthe PVO6 small and medium capacity RAM memory cards product version written on the card label i e offering memory size under Unity 768K TSX MRP P 128K TSX MRP P 224K TSX MCP C 224K MCP C 512K TSX MRP P 384K TSX MRP C 448K TSX MRP C 768K e under Unity whose version is gt 2 02 S68 state of the This bit is used to check the operating state of the no yes PLCBAT processor backup battery for saving data and the program in battery RAM setto 0 battery present and operational setto 1 battery missing or non operational S75 state of the This bit is used to monitor the status of the main battery no no PCMCIABAT1 data when the memory card is in the lower PCMCIA slot see storage chapter System Bits in the Unity Pro Program memory Languages and Structure Reference Manual card battery Note Data stored on a memory card in slot B are not processed in SIL3 projects 33003879 01 2010 139 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Bit Function Description Initial Write Quant Symbol State Access Safety 96976 configured This bit is set to 1 by the system when the diagnostics 0 no yes DIAGBUFFCONF diagnostics option has been configured Then a diagnostics buffer buffer for storage of errors found by diagnostics
67. apters Chapter Chapter Name Page A IEC 61508 123 B System Objects 131 33003879 01 2010 121 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 122 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com IEC 61508 A Introduction This chapter provides information on the Safety concepts of the IEC 61508 in general and its SIL policy in particular What s in this Chapter This chapter contains the following topics Topic Page General Information on the IEC 61508 124 SIL Policy 126 33003879 01 2010 123 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com General Information on the IEC 61508 Introduction Safety Related Systems are developed for use in processes in which risks to humans environment equipment and production must be kept at an acceptable level The risk depends on the severity and likelihood thereby defining the necessary measures of protection Concerning the Safety of processes there are 2 sides to be considered e the regulations and requirements defined by official authorities in order to protect humans environment equipment and production e the measures by which these regulations and requirements are fulfilled IEC 61508 Description The technical standard defining the requirements for Safety Related Systems
68. ata stored on a memory card in slot B is not processed in SIL3 projects Failure to follow these instructions can result in death serious injury or equipment damage In addition to the standard Quantum Hot Standby functions you can also use the Quantum Safety PLCs for Safety Related Hot Standby systems in order to achieve high availability for the CPU in a Safety Related System To control the ability of the standby PLC to take over from the primary you can use an elementary function block EFB to program an automatic swap between primary and standby PLC For further information on this topic see also Hot Standby Safety CPU Specifics page 35 To achieve high availability for the I O you can also use the Safety I Os in a redundant manner For further information on this topic see also Configuration Examples for the Quantum Safety PLC page 60 33003879 01 2010 27 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Training Introduction As stated in the IEC 61508 Part 1 App B all persons involved in a Safety Lifecycle activity should have the appropriate training technical knowledge experience and qualifications relevant to the specific duties they have to perform This should be assessed in relation to each particular application NOTE Make sure you possess all information and skills required to install run and maintain Safety Related Systems correctly T
69. be on separate modules wired in parallel and connected to 1 actuator The following figure illustrates the redundant digital output configuration ue The following figure shows the electrical scheme for this configuration Process Output CPU module 1 Qi oj A function block is not necessary because the same signal from the CPU is connected to both outputs 42 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Safety I O Modules Diagnostics Description of the I O Diagnostics The following table lists the field diagnostics of the Safety I O modules Diagnostics Analog Input Digital Input Digital Output Out of Range yes Broken Wire yes yes Field Power yes yes Overload yes NOTE Shor circuit of the wiring is not detected for the input modules It is your responsibility to make sure that the modules are wired correctly see the Quantum with Unity Pro Discrete and Analog I O Reference Manual In addition the Quantum Safety PLC provides diagnostics of the communication between Safety CPU and Safety I O modules for instance a CRC Thus itis not only checked that the data received are the data sent but also that the data are updated To handle disturbances for example by EMC effects which may temporarily corrupt your data you can configure a maximum accepted consecutive CRC error for each module ra
70. bility of failure on demand 127 PFH probability of failure per hour 17 20 33003879 01 2010 175 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Index 127 PLC programmable logic controller 15 PLC cycle time 71 PLC reaction time 71 PLCBAT 139 PLCRUNNING 135 probability of failure on demand PFD 17 20 127 probability of failure per hour PFH 17 20 127 process Safety time PST 34 71 programmable logic controller PLC 15 proof test interval PTI 17 22 PST process Safety time 34 71 PTI proof test interval 17 22 pulse test 50 Q Quantum Safety CPU internal 1002 architecture 33 Quantum Safety I O 39 55 R REMIOERR 140 remote I O RIO 39 55 RIO remote I O 39 55 RSTMSGCNT 740 RTCERR 138 RTCTUNING 139 RTCWRITE 138 S safe failure fraction SFF 127 Safety FFB Safety function function block 79 Safety FFB library 79 94 Safety function function block Safety FFB 79 Safety Integrity Level SIL 126 Safety loop 20 129 Safety memory area 101 101 Safety Mode 23 87 error state 87 run state 87 Safety move function block 103 SAVECURRVAL 140 SEC 146 Security Editor 78 SFF safe failure fraction 127 SIL 17 SIL Safety Integrity Level 126 STOPDAY 147 STOPHM 147 STOPMD 147 STOPSEC 147 STOPYEAR 147 STRINGERROR 136 T TB100MS 134 TB10MS 134 TB1MIN 134 TB1SEC 134 time o
71. ct is Then in stop state and the autorun option activated either power on your PLC again or perform a Run command in stop state and the autorun option not activated perform a Run command in no conf state download a backup of your project Fault Behavior in Maintenance Mode Running in Maintenance Mode your PLC enters e halt state in case of a diagnostic error e error state in case of a hardware watchdog occurrence If the PLC is in halt state you still have the possibility to communicate with it and therefore to debug your project With the Init command or the download of a project the PLC goes to stop state and can now be restarted If the PLC is in error state the behavior is the same as described above in Fault Behavior in Safety Mode 33003879 01 2010 99 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 3 5 Communication Introduction This section deals with the communication of the Quantum Safety PLC with Unity Pro XLS as well as with other devices What s in this Section This section contains the following topics Topic Page Memory Area 101 PC PLC Communication 104 PLC PLC Communication 105 PLC HMI Communication 107 100 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 33003879 01 2010 Memory Area Introduction In Safety Mode the Saf
72. d redundancy capacity of a Safety Related System D in 1002D refers to diagnostics Hence D in 1002D means 1 out of 2 with diagnostics 33003879 01 2010 155 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary ALARP as low as is reasonably practicable Definition IEC 61508 Fisk cannot be justified except in extraomdirnia ry circumstances The ALARP or Talerable only if further risk tolerability regon reduction is impracticable or if its costis grossly dsproporticrate to the improvement gained Risk is undertaken only if a benefit is desired As the risk is reduced sois thenecessity to incur cost to reduce the risk further in order to fulfil ALARP The tiange illustrates the concept of diminishing proportion Broadly acceptable region Itis necessary to maintain safeguards so as to keep risk at this level No need for detailed working to demonstrate ALARF Negligible risk CCF common cause failure failure which is the result of 1 or more events causing coincident failures of 2 or more separate channels in a multiple channel system leading to system failure Definition IEC 61508 The common cause factor in a dual channel system is the crucial factor for the probability of failure on demand PFD for the whole system 156 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary
73. dby CPU The Hot Standby Safety CPU differs from the standalone Safety CPU in the use of the Ethernet port In the standalone Safety CPU it is used to communicate with other devices using a normal Ethernet cable In the Hot Standby Safety CPU it is used to exchange data between the Primary CPU and the Standby CPU controller using a fiber optic link Because the fiber optic link is not part of the Safety loop the PFD and PFH values of the Hot Standby CPU are the same as those of the standalone CPU Each Safety CPU includes a PCMCIA memory card see page 19 but its use and presence is not mandatory Description of the Hot Standby Configuration The Hot Standby configuration contains 2 identical local racks and at least 1 remote I O drop because I Os cannot be placed in the local rack of a Hot Standby configuration Besides a power supply module must be at least one 140 CPS 124 20 each local rack must consist of both a e 140 CPU 671 60S module e 140 CRP 932 00 module Besides a power supply and I O modules must be at least one 140 CPS 124 20 the remote drop s must include a 140 CRA 932 00 module CAUTION UNINTENDED EQUIPMENT OPERATION Only high availability RIO modules which provide dual cabling are allowed in a Safety Related System Failure to follow these instructions can result in injury or equipment damage For Hot Standby configuration example refer to the information on Connecting the Remote l
74. des the image of the positions of 0 no yes KEY_SWITCH switches on the the switches on the front panel of the Quantum Quantum front processor This word is updated automatically by panel the system e SW71 0 1 switch in the Memory protected position SW71 1 1 switch in the STOP position e SW71 2 1 switch in the START position e SW71 8 1 switch in the MEM position e SW71 9 1 switch in the ASCII position SW71 10 1 switch in the RTU position e SW71 3 to 7 and 11 to 15 are not used SW75 timer type see chapter System Objects in the Unity Pro 0 no TIMEREVTNB event counter Program Languages and Structure Reference Manual SW76 diagnostics Result of the last registration 0 yes DLASTREG function e Oif the recording was successful recording e 1 if the diagnostics buffer has not been configured e 2ifthe diagnostics buffer is full SW77 diagnostics Result of the last deregistration 0 yes DLASTDEREG function non e O if the non recording was successful recording e 1 if the diagnostics buffer has not been configured e 21 if the error identifier is invalid e 22ifthe error has not been recorded SW78 diagnostics Number of errors currently in the diagnostics 0 yes DNBERRBUF function buffer number of errors 150 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects
75. dule Field side CPU side Backplane ADC Analog to Digital Converter DAC Digital to Analog Converter Diag Internal Diagnostics DPM Dual Port Memory Isol Electrical Isolation uP Micro Processor Wiring Information In order to ensure appropriate shielding characteristics of the wiring you must use grounding equipment for the analog input shielded wires Schneider Electric recommends using the following devices from the Advantys STB catalog MKTED206061 EN or similar equipment e Grounding Kit part number STB XSP 3000 e Terminals for Grounding Kit part number STB XSP 3010 or STB XSP 3020 Unused inputs is signaled as unhealthy because of the Safety analog input module s open circuit detection The health bit of unused inputs should be masked in the health word of the module in your application logic 33003879 01 2010 45 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Usage in Burner Management Applications In burner management applications the Safety analog input modules must be monitored for ground faults leakage of current The wires should be connected potential free With a shunt resistor for instance 250 Q between the ground rail of the grounding kit and the earth ground a voltage can be measured in case of a leakage of the current on 1 of the analog inputs This voltage must be supervised to detect a leakage Description of the Diagnostics The field side c
76. e In addition it is possible to define a maximum number of accepted CRC faults NcRc for the communication with the I Os This has been introduced to reduce spurious effects for instance by an EMC disturbance This number can be defined to take a value between 1 and 3 This must be taken into account because the number of cycles for the output module to react is increased Therefore the equation above is extended as follows CPU reaction time 2 Ncc x CPU cycle time Description of the Time for Input Modules The maximum times worst case for the Safety digital input module and for the Safety analog input module T are 45 ms 3 times the module s cycle time Description of the Time for Output Modules The maximum time To for the Safety digital output module is equal to the cycle time of the module To 2 15 ms For the Safety digital output module a timeout Tour must be configured The module timeout must be greater than the CPU cycle time see below You can find a detailed procedure for configuring the module timeout of digital output modules in the chapter Configuring I O Modules for Safety Projects in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics 72 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Description of the Maximum CPU Cycle Time Knowing the required PST and the maximum reaction time of the sensors and actuators you are able to c
77. e the Safety PLC may be connected to other PLCs and communicate data when requested or even accept data in the unrestricted memory area Description of the Ethernet Communication The Ethernet network can be connected to e either the Ethernet port of the CPU e orthe Ethernet module 140 NOE 771 11 NOTE In case of a Hot Standby Safety CPU the Ethernet port is used for the data exchange between the primary and the standby CPU and therefore not available for the communication with other PLCs or HMls The Ethernet module 140 NOE 771 11 is certified as non interfering product for use in the Quantum Safety PLC The communication can be either peer to peer or as global data For the Ethernet cabling the standard Ethernet devices can be used Configuring the Ethernet Peer to Peer Communication The peer to peer communication is configured in Unity Pro XLS in the Ethernet network configuration independently for reading and writing Unity Pro XLS checks that reading uses only the unrestricted memory area It creates an error and does not generate code if this rule is not obeyed 33003879 01 2010 105 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Configuring the Ethernet Global Data Communication The global data communication is configured in Unity Pro XLS in the Ethernet network configuration to publish data for writing and to subscribe to data for reading Because reading is only allo
78. e mapped to the Safety memory range the unrestricted memory area can only be used with S S MOVE function blocks Failure to follow these instructions can result in injury or equipment damage The Unity PRO XLS cannot check this rule so the user is responsible for the separation of safety logic and non safety logic It is recommended to use separate sections to facilitate the verification 54 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 2 5 Restrictions on I O Modules Description of the Restrictions on I O Modules Introduction With regard to the communication between the Quantum Safety CPU and I O modules you must observe the following restrictions on I O modules e Communicating to I O via Ethernet or Modbus Plus is not allowed on a Quantum Safety PLC Unity Pro XLS cannot check for compliance with this rule because Ethernet and Modbus Plus communication to other PLCs not I Os are allowed see also PLC PLC Communication Description see page 105 4 DANGER UNCERTIFIED DATA TRANSFER SIL3 VIOLATION Do not configure Ethernet or Modbus Plus I Os in your Safety PLC It is your responsibility to guarantee that no communication occurs to I O via Ethernet or Modbus Plus Any violation of this rule makes your application non IEC 61508 compliant Failure to follow these instructions will result in death or serious injury e Distrib
79. e module see Quantum Safety I O Modules in the Quantum with Unity Pro Discrete and Analog I O Reference Manual Depending on the type of detected error the complete module may have to be exchanged Detected Module Error If a module error is detected the I O module enters the Safe state It then resets restart sand performs the power up self tests If the power up self tests Then the module are successful starts and operates normally are unsuccessful resets and goes through the same procedure NOTE If several self tests are unsuccessful the module must be exchanged After a detected error in a Safety I O module it restarts automatically If the power up self tests are successful the module continues normal operation i e it again sets the outputs to 1 If an inoperable module has been exchanged hot swapped it also automatically starts operation after the self test The application must be programmed and configured in such a way that it behaves correctly after restart of the Safety I O modules A WARNING UNEXPECTED APPLICATION BEHAVIOR AUTOMATIC RESTART Program and configure the system in such a way that it behaves correctly after the Safety I O modules restart Failure to follow these instructions can result in death serious injury or equipment damage 33003879 01 2010 59 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com
80. e of your unrestricted memory area in Unity Pro XLS in the CPU configuration with the following limits e In MW the limit is e the last word in the unrestricted area or e Oif this area is not used e In 96M the limit is e amultiple of 16 and the last M in the unrestricted area or e Oifitis not used NOTE Configure the unrestricted memory area first and confirm that the configured area is large enough If this part of the memory must be modified later all addresses must be changed CAUTION RISK OF CORRUPT PROJECT Check that the size of the unrestricted memory area is correctly stored in the Quantum Safety CPU after the download of the PLC application To do so you must read the system words SW110 and SW111 for instance using the animation table and compare them with the configured values in your application Failure to follow these instructions can result in injury or equipment damage Using Data from the Unrestricted Memory Area To perform Safety Functions you are only allowed to process data stored in the Safety memory area If it is necessary to get access to the Safety Functions you are allowed to use data from the unrestricted memory data However for Safety reasons you cannot process them directly Instead you must transfer data from the unrestricted memory area to the Safety memory area in order for Safety Functions to use these data You can find a detailed procedure for transferring data from t
81. e primary CPU it takes over the role of the primary CPU executing the user logic and processing the I O Therefore the output modules must filter the lack of exchange with the primary CPU to avoid glitches when a switch occurs This is achieved by configuring the output module timeout As a result the PLC reaction time is greater than the timeout configured in the output module thereby influencing the process Safety time NOTE The behavior of the Hot Standby Safety CPU is equivalent to that of the standalone Safety CPU In case of a detected error the PLC enters e Halt state when running in Maintenance Mode e Error state when running in Safety Mode 36 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Availability of the Hot Standby Functions In addition to the standard Hot Standby functions you can use an EFB to program an automatic swap between primary CPU and Standby CPU PLC in order to verify the ability of the Standby CPU PLC to take over from the primary CPU That means that the Standby CPU PLC periodically becomes the primary CPU and the primary CPU PLC the Standby CPU It is recommended to avoid using the USB link during swap The following table lists the available Hot Standby functions in Maintenance Mode and Safety Mode Function Maintenance Mode Safety Mode Hot Standby yes yes Switch Over yes yes EFB Swap no yes
82. ections which are only used for non Safety logic of the system The data from non interfering modules should be processed in these sections only which makes the certification of your project much easier NOTE To operate the Quantum Safety PLCs and to program and run your SIL3 project you need the certified Safety version of the Quantum firmware For details see Certified Products page 22 Probabilities of Failure For SIL3 applications the IEC 61508 defines the following probabilities of failure on demand PFD and probabilities of failure per hour PFH depending on the mode of operation e PFD gt 10 to lt 10 for low demand mode of operation e PFH gt 10 to lt 10 for high demand mode of operation The Quantum Safety PLC is certified for use in low and high demand systems Safety Loop Description The Safety loop to which the Quantum Safety PLC consists of the following 3 parts e Sensors e Quantum Safety PLC with Safety CPU and Safety I O modules e Actuators A backplane or a remote connection with CRA CRP do not destroy a Safety Loop Backplanes CRP and CRA modules are part of a black channel This means that the data exchanged by I O and PLC cannot be corrupted without detection by the receiver 20 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com The following figure shows a typical Safety loop SAFETY LOOP T Input CPU Output ofP
83. ectric Co Inc 800 473 9123 www barr thorp com 113 Checklist for I O Modules Introduction This list is not exhaustive and you are fully responsible for observing all Safety requirements mentioned in the IEC 61508 as well as in this manual Checklist for the I O Modules Schneider Electric recommends that you use the following checklist for your I O modules Checks Reference in this Manual Done Remarks Do not use Ethernet I Os restrictions on I Os Do not use Modbus Plus l Os restrictions on I Os Do not use non interfering I Os for Safety descr of I O modules Related functions see page 54 The wiring of the digital inputs must be de wiring of SDI energized to trip a wiring fault must be see page 47 equivalent to the de energized state Use appropriate grounding equipment for the wiring of SAI analog input shielded wires see page 45 In burner management applications the analog inputs must be monitored for grounding faults leakage of current special req for appl standard see page 119 Check that the configured timeout state of the output modules is appropriate for the connected device and the controlled process description of the timeout state In a redundant I O system use the 2 I O channels on separate modules which should be located in separate drops redundant I O configuration see page 63 Use an appropriate wire
84. ensors and other input devices data highways and other communication paths and actuators and other output devices EDT elementary data type An elementary data type is predefined EF elementary function EFB elementary function block EMC electromagnetic compatibility The term refers to the origin control and measurement of electromagnetic effects on electronic systems 158 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary EN error ESD EUC failure fault FBD FFB European Norm This is the official European standard discrepancy between a computed observed or measured value or condition and the true specified or theoretically correct value or condition Definition IEC 61508 emergency shutdown equipment under control Definition IEC 61508 This term designates equipment machinery apparatuses or plants used for manufacturing process transportation medical or other activities F termination of the ability of a functional unit to perform a required function Definition IEC 61508 abnormal condition that may cause a reduction in or loss of the capability of a functional unit to perform a required function Definition IEC 61508 functional block diagram This is an IEC 61131 3 programming language for PLC user logic function function block 33003879 01 2010 159 This document provided by Barr Thorp Electric Co
85. ents When devices are used for applications with technical safety requirements the relevant instructions must be followed Failure to use Schneider Electric software or approved software with our hardware products may result in injury harm or improper operating results Failure to observe this information can result in injury or equipment damage 2010 Schneider Electric All rights reserved 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Table of Contents Safety Information lllses 7 About the BOOK poter E me Re ee viens 9 Chapter 1 General Information on the Quantum Safety PLC 13 1 1 General Information s s ame e aces xe Gas bea be Kua awe EUR Ru RUE Ra Swe 14 IEC 61508 and Safety Integrity Level SIL 0 15 Functional Safety Certification sisse Rr rx 16 Special Operating Modes 0 0 0 c eee eee eee 23 DIAQNOSUCS 4 RT 24 Difference Between Standard Quantum PLC and Quantum Safety PLC 25 TRAINING sem mmm rp puce m awed wee ns wes iEn ei s 28 1 2 Safety Requirements lt lt sss ses EQ Exe X RREREREeERYRERa 29 Requirements for Hardware and Programming lilius 29 Chapter 2 Hardware and Configuration 31 2 1 Salety CPU cissvebizssxskkewek i ETER ENEY ee veges ERE aes 32 Standalone Safety CPU zossseraas bed ees bane care ees Oh bes ener 33 Hot Standby Safet
86. equirements of the Safety Functions to be allocated to the Safety Related Systems where Safety Integrity Level 4 has the highest level of Safety Integrity and Safety Integrity Level 1 has the lowest see S Ls for Low Demand page 128 SIL Requirements Description To achieve Functional Safety 2 types of requirements are necessary e Safety Function requirements defining what Safety Functions have to be performed e Safety Integrity requirements defining what degree of certainty is necessary that the Safety Functions are performed The Safety Function requirements are derived from hazard analysis and the Safety Integrity ones from risk assessment They consist of the following quantities Mean time between failures Probabilities of failure Failure rates Diagnostic coverage Safe failure fraction e Hardware fault tolerance Depending on the level of Safety Integrity these quantities must range between defined limits 126 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com SIL Rating Description As defined in the IEC 61508 the SIL value is limited by both the Safe Failure Fraction SFF and the hardware fault tolerance HFT of the subsystem that performs the Safety Function A HFT of n means that n 1 faults could cause a loss of the Safety Function the Safe state cannot be entered The SFF depends on failure rates and diagnostic coverage The following table show
87. essment and describe the likelihood of a Safety Function to be performed satisfactorily for instance the degree of certainty necessary for the Safety Function to be carried out sniffing reading the configuration out of a PLC SRS safety requirements specification specification containing all the requirements of the safety functions that have to be performed by the safety related systems Definition IEC 61508 168 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary SSC system Safety concept This is a detailed description of the system architecture configuration and diagnostics required to achieve Functional Safety ST structured text This is an IEC 61131 3 programming language for PLC user logic Statement of Consequence This is the last line within all special messages It begins with Failure to follow these instructions systematic failure failure related in a deterministic way to a certain cause which can only be eliminated by a modification of the design or of the manufacturing process operational procedures documentation or other relevant factors Definition IEC 61508 T TUV Technischer Uberwachungsverein German for Association for Technical Inspection UMA unrestricted memory area It is a specially dedicated memory area for bits and words which is not write protected 33003879 01 2010 169 This document provided by Barr
88. etected diagnostic error In addition a complete commissioning of the safety application has to be performed The complete procedure must include the necessary tests of cabling sensors and actuators depending on the full application analysis 30 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Hardware and Configuration Introduction This chapter provides information conceming hardware and configuration of the Schneider Electric products that can be used for SIL3 applications What s in this Chapter This chapter contains the following sections Section Topic Page 2 1 Safety CPU 32 2 2 Safety I O Modules 38 2 3 Power Supply 52 2 4 Non Interfering Modules 53 2 5 Restrictions on I O Modules 55 2 6 System Behavior in Case of Detected Diagnostic Errors 56 2 7 Configuration Examples 60 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 2 1 Safety CPU Introduction The following section introduces the internal architecture of the Quantum Safety CPUS distinguished according to their use in standalone and Hot Standby solutions What s in this Section This section contains the following topics Topic Page Standalone Safety CPU 33 Hot Standby Safety CPU Specifics 35 32 This document provided by Barr Thorp Electric Co Inc 800 473
89. ety CPU rejects all write requests to the following memory areas e 96M or Q 0x register e MW or QW 4x register e EFB data However because it may be necessary for you to be able to write data to the Safety PLC the memory is divided into a Safety and an unrestricted part allowing you to write in M as well as in MW Safety Memory Description The Safety memory area is write protected for any other device NOTE The write access is controlled inside the CPU because some communications for example with the HMI or with other PLCs Safety or non Safety are not configured in the Safety PLC with Unity Pro XLS and therefore cannot be checked in the Unity Pro XLS configuration Write Protection Description To prevent other devices from writing to the Safety memory area there is a blocking mechanism The PLC does not execute any write command and returns an error code Unrestricted Memory Area Description The unrestricted memory area UMA is a specially dedicated memory area for bits and words which is not write protected It has the following characteristics e It is located at the beginning of the complete memory range e Its size can be configured in Unity Pro XLS e Its values cannot be used directly but by using specific function blocks 33003879 01 2010 101 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Configuring the Unrestricted Memory Area You can configure the siz
90. ey are not allowed to write Safety data directly see also PLC HMI Communication page 107 33003879 01 2010 61 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Redundant CPU Configurations for High Availability 1002 HotStandby system The following figure is an example of a Hot Standby Quantum Safety PLC consisting of redundant CPUs HSBY link The following figure provides the appropriate functional overview Standby T uator Sensor Pri mary 62 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Redundant I O Configurations for High Availability The following figure provides the functional overview of a redundant I O configuration consisting of 1 CPU and redundant l Os Sensor Actuator Sensor It is possible to place your redundant Safety I O modules e either in the same RIO drop not recommended e orin different RIO drops recommended when redundant Safety I O modules are used The following figure shows redundant I Os placed in the same RIO drop left and in different RIO drops right ees Redundant modules NOTE Schneider Electric recommends always placing redundant Safety I O modules in different RIO drops 33003879 01 2010 63 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Redundant CPU and I O Configuration The foll
91. f statistical functions Name Type Used S_MIN_ EF to assign the smallest input value to the output S MAX EF to assign the largest input value to the output S LIMIT EF to transfer the unchanged input value to the output if it lies within the minimum and the maximum limit S MUX EF to transfer the respective input value to the output depending on the K input value S SEL EF for a binary selection between 2 input values Description of the Safety FFBs for Timers and Counters The following table lists the Safety FFBs belonging to the family of timer and counter functions Name Type Used S_CTU_ EFB _ for counting upwards S GTD EFB for counting downwards S GTUD EFB for counting upwards and downwards S TON EFB as on delay timer S TOF EFB as off delay timer S TP EFB for generating a pulse with defined duration 33003879 01 2010 81 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Description of the Safety FFBs for Type Conversion The following table lists the Safety FFBs belonging to the family of type conversion functions Name Type Used to convert an input value of the data type S BOOL TO EF BOOL
92. f the Safety I O page 16 modules is displayed on the label on the housing 110 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com page 70 Safety Mode Restrictions page 87 Process Safety Time page 71 Checks Reference in Done Remarks this Manual Configure the maximum scan time correctly and appropriately to Requirements the process for Monitoring O Use an application password to protect your SIL3 application against unauthorized access Application Password page 83 Use only high availability RIO modules 140 CRP 932 00 and 140 CRA 932 00 which provide dual cabling Description of the RIO Adapters page 53 Description of the CPU I O Communication page 39 Protect the process power supply of the digital output modules by an appropriate fuse Wiring Information page 50 Use 2 power supply modules per rack and drop to improve the availability of your system Mounting the 2 power supply modules on each end of the rack or drop provides better heat dissipation Power Supply for the Quantum Safety PLC page 52 Check in each drop that 1 power supply module is able to deliver the complete power consumption Power Supply for the Quantum Safety PLC page 52 Make sure that the addresses of all CRA modules are configured correctly Description of the RIO Adapters page 53 Do not w
93. fety PLC are protected by the following password mechanisms e The SIL3 project is protected by a password at the application level the application password When you create a SIL3 project an empty password which you can change is set e The Quantum Safety PLC is also protected by the application password In case there is no application in the PLC it accepts any password e Connecting to a Safety PLC requires to enter the application password if the currently opened project in Unity Pro XLS is different or no project is opened 33003879 01 2010 77 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Unity Pro XLS itself is protected by the following mechanisms e You can define access rights or a list of functions a user is allowed to perform using the Security Editor provided together with Unity Pro XLS and having the same functionality as in Unity Pro XL e Aftera configured time of inactivity Unity Pro XLS is locked automatically Before being able to continue to work with it you must enter the application password While Unity Pro XLS is locked the connection to the PLC is maintained and it stays in the current mode Description of the Security Editor To protect Unity Pro XLS against unauthorized access you can use the Security Editor e to apply a policy and to create profiles and users for it e to manage access rights to it For example you can restrict the access for e c
94. figured The value must be compliant with the PLC cycle time the Hot Standby configuration if HSBY is used and the process Safety time see Process Safety Time page 71 In case of permanent bad exchanges with the CPU the digital output module reboots after a fixed time out of 65 seconds this causes all outputs to go to O independent of the configured time out state 33003879 01 2010 51 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 2 3 Power Supply Power Supply for the Quantum Safety PLC Introduction For use in the Quantum Safety PLC the 140 CPS 124 20 Quantum power supply module is certified This CPS is certified even if neither PFH nor PFD values are provided It cannot deliver a higher voltage than the one supported by all the safety modules A WARNING LOSS OF THE ABILITY TO PERFORM SAFETY FUNCTIONS Do not use power supply modules other than the Quantum 140 CPS 124 20 Failure to follow these instructions can result in death serious injury or equipment damage Description of the Module Features This module has an over voltage protection and detection Further it supports redundancy If a fault is detected the other one will take over and supply the rack with the necessary power NOTE Schneider Electric recommends always using 2 Quantum power supply modules per rack in the Quantum Safety PLC NOTE 1 power supply module 140 CPS 124
95. follow these instructions can result in death serious injury or equipment damage You can find the most recent information on the certified product versions on the TUV Rheinland Group website http www tuvasi com under Information and further List of Type Approved Programmable Electronic Systems 22 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Special Operating Modes Introduction With regard to Functional Safety aspects the following 2 operating modes of the Quantum Safety PLC are of special importance e the Safety Mode e the Maintenance Mode Safety Mode Description The Safety Mode is the default mode of the Quantum Safety PLC in which the Safety Functions are performed to control the process It is a restricted mode in which modifications and maintenance activities are prohibited You are only allowed to stop and start the PLC You can find a detailed description of the Safety Mode in Safety Mode page 87 Maintenance Mode Description The Maintenance Mode of the Quantum Safety PLC is a temporary mode for debugging and maintaining your program You are allowed to force values and to modify the program In the Maintenance Mode the STOP or RUN diagnostics are not available A WARNING LOSS OF ABILITY TO PERFORM SAFETY FUNCTIONS In Maintenance Mode all diagnostic functions are performed but their results are not fully evaluated O
96. formed NOTE The process Safety time is given by the process It must be ensured that the Safety Related System is able to perform the Safety Functions within the process Safety time Description of the System Reaction Time The system reaction time is the sum of the PLC reaction time and the time for the used sensor device Ts and the time for the used actuator device T4 Ts and T4 are device specific The following equation is valid System reaction time PLC reaction time Ts TA This equation is illustrated below PLC reaction time T Tay To System reaction time T T Tou To T The system reaction time must be less than the process Safety time Description of the PLC Reaction Time The PLC reaction time is the sum of the related time for the used input module T and the used output module To and the CPU reaction time Tcp The following equation is valid PLC reaction time Tcpy Tj To 33003879 01 2010 71 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Description of the CPU Reaction Time The CPU reaction time is directly impacted by the CPU cycle time which is needed to execute the Safety logic A signal may appear just at the beginning of the execution cycle when the signals have already been processed Therefore 2 cycles may be necessary to react to the signal This leads to the following equation CPU reaction time 2 x CPU cycle tim
97. gram Languages and Structure Reference Manual SW1 fast task see chapter System Objects see Unity Pro 0 yes no FASTPERIOD scanning Program Languages and Structure Reference period Manual in the Unity Pro Program Languages and Structure Reference Manual SW2 SW3 auxiliary task see chapter System Objects see Unity Pro 0 yes no SW4 SW5 scanning Program Languages and Structure Reference period Manual in the Unity Pro Program Languages and Structure Reference Manual SW8 acquisition of see chapter System Objects see Unity Pro 0 yes no TSKINHIBIN task input Program Languages and Structure Reference monitoring Manual inthe Unity Pro Program Languages and Structure Reference Manual SW9I monitoring of see chapter System Objects see Unity Pro 0 yes no TSKINHIBOUT _ task output Program Languages and Structure Reference update Manual in the Unity Pro Program Languages and Structure Reference Manual SW10 first cycle see chapter System Objects see Unity Pro 0 no no TSKINIT after cold Program Languages and Structure Reference start Manual inthe Unity Pro Program Languages and Structure Reference Manual SW11 watchdog Reads the duration of the watchdog The duration no yes WDGVALUE duration is expressed in milliseconds 10 1500 ms This word cannot be modified 142 33003879 01 2010 System Objects This document provided by Barr Thorp
98. he unrestricted to the Safety memory area in the chapter Using Data from the Unrestricted Memory Area in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics 102 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Description of the Safety Move Function Blocks Because you are not able to work with the values located in the unrestricted memory area directly there are the following 2 function blocks enabling you to transfer data from the unrestricted memory area to the Safety memory UJ e S SMOVE BIT to get access to bits e S SMOVE WORD to get access to words The variables from the unrestricted memory area are connected to the input of the function block and its output is connected to a Safety variable Direct addresses cannot be used because they are interpreted as INT The WORD to be moved must be configured in the unrestricted memory area If the actual value is not within the range the output is set to 0 and the error is indicated Additional inputs are used to control how the function blocks transfer the data to the outputs in case some data can only be used together in the same cycle NOTE It is good practice to use an appropriate naming convention for variables from the unrestricted memory area and to comment them accordingly This eases the audit of your SIL3 project The user can use data in the safety application by implementing a
99. he values are not the same and Unity Pro XLS does not open your project As a result you cannot connect Unity Pro XLS to the Safety PLC and therefore have no possibility of modifying or repairing your corrupt project Project Backup Description Besides uploading the project from the PLC see Upload page 97 the only way to get access to your project is to have a copy of its original that is a backup of your project From this backup you can copy back your project data that is restore them NOTE Create backups of your SIL3 project on a regular basis Once your project is damaged or corrupted you cannot open it to modify or repair it yourself Advice for Creating Backups Creating backups requires careful planning including consideration of e Backup software Automated backup cannot be affected by human error to the extent that manual backup can e Backup procedure Making more than 1 copy and storing them offsite increases the possibility of a successful data recovery e Backup type In general a backup can be full incremental or differential depending on which data it backs up e Backup interval Regularly scheduled backups improve the reliability of data recovery e Backup media type Whereas hard disk based storage is very practical remote backups imply offsite storage Advice for Recovering Data A backup is only as useful as its associated recovery strategy Therefore it is not only important to save the backup data bu
100. ibrary 82 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Application Password Password Protection Management In the following situations you are requested to enter the application password e opening an existing SIL2 or SIL3 project e modifying the application password e clearing the application password e connecting to the Safety PLC e exceeding the configured time of inactivity and launching the auto lock mechanism You can find detailed procedures for managing the application password in the chapter Project Properties and Password for Unity Pro XLS in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics NOTE Schneider Electric strongly recommends changing the default password immediately after having selected a Quantum Safety CPU in order to protect your project against unauthorized access from the beginning Yet if you forget to change the default password the empty password is kept even if you save and close your project When re opening it just click OK that is leave the edit field empty and change the password as soon as possible Losing the Application Password You can find detailed procedures for whatto do in case you have lost the application password in the chapter Loss of Password see Unity Pro XLS Software Operating Mode Manual Safety PLC Specifics in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics 33003879 01
101. intenance personnel Safety I O Modules in High Availability Configurations page 40 Signal a fault in 1 cable of the dual cable remote I O system to the maintenance personnel Description of the Hot Standby Configuration page 35 Description of the RIO Adapters page 53 Description of the CPU I O Communication page 39 In a redundant power supply configuration signal a fault of 1 of the 2 power supply modules to the maintenance personnel Power Supply for the Quantum Safety PLC page 52 In a HSBY system use the s HSBY SWAP function block regularly for example once a week to check the ability of the standby controller to take over Availability of the Hot Standby Functions page 37 When replacing a CRA module make sure that the address is Description of configured correctly the RIO Adapters page 53 Make sure that your personnel possess all information and skills Training required to install run and maintain the Safety Related System page 28 E correctly Make sure to follow the specified operating conditions regarding Hardware EMC electrical mechanical and climatic influences Requirements ia page 29 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 117 4 DANGER RISK OF LOSING THE SAFETY FUNCTION DURING COMMISSIONING AND MAINTENANCE All modifications of the running system must fo
102. irements for Programming page 68 and Special Requirements for Application Standards page 1 19 Classification of the Schneider Electric Products The Quantum Safety PLC consists of Safety modules which are allowed to perform Safety Functions However it also supports so called non interfering modules thereby enabling you to add non Safety parts to your SIL3 project Therefore the Schneider Electric products must be distinguished into e Safety modules and e non interfering modules In contrast to the Safety modules non interfering modules are not used to perform Safety Functions They are certified as non interfering modules for use in the Quantum Safety PLC A fault in 1 of these modules does not influence the execution of the Safety Functions in a negative way 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Available Safety Products Schneider Electric offers the following Safety modules certified for use in SIL3 applications The Safety modules are listed with their corresponding PFD PFH values for different proof test intervals PTIs see Probabilities of Failure page 20 and Proof Test Interval page 22 The PFD PFH are expressed as values that contributes to the overall PFD PFH of the complete Safety loop see Safety Loop Description page 20 and Safety Loop Description page 129 The values are given for SIL3 applications The tables below list the Safety
103. is e the IEC 61508 It deals with the Functional Safety of electrical electronic or programmable electronic Safety Related Systems A Safety Related System is a system that is required to perform 1 or more specific functions to ensure risks are kept at an acceptable level Such functions are defined as Safety Functions A system is defined functionally Safe if random systematic and common cause failures do not lead to malfunctioning of the system and do not result in injury or death of humans spills to the environment and loss of equipment and production The standard defines a generic approach to all lifecycle activities for systems that are used to perform Safety Functions It constitutes procedures to be used for the design the development and the validation of both hardware and software applied in Safety Related Systems Further it determines rules concerning both the management of Functional Safety and documentation IEC 61511 Description The Functional Safety requirements defined in the IEC 61508 are refined specifically for the process industry sector in the following technical standard e the IEC 61511 Functional safety safety instrumented systems for the process industry sector This standard guides the user in the application of a Safety Related System starting from the earliest phase of a project continuing through the start up covering modifications and eventual decommissioning activities In summary it deals with the
104. its and retransmissions Therefore the non interfering modules such as backplanes remote I O adapters 140 CRP 932 00 and 140 CRA 932 00 can be used inside the safety loop without impact on the PFD and PFH evaluations For further details see General Information on the Safety I O Modules page 39 24 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Differences Between Standard and Safety PLC Difference Between Standard Quantum PLC and Quantum Safety PLC To meet the requirements of the IEC 61508 standard the Quantum Safety PLC differs from the standard Quantum PLC The following table lists the main differences between a standard Quantum and a Safety Quantum PLC Feature Standard Quantum PLC Quantum Safety PLC CPU Program Execution executed on application processor or Intel executed on application processor and Intel warm start Configuration e backplane backplane local rack local rack e remote I O e remote I O all power supplies e dedicated power supply backplane expanders e distributed I O e fieldbus I O Firmware regular firmware Safety firmware Software e Unity Pro XLS e Unity Pro XLS e Unity Pro XL e Unity ProL User Logic e FBD e FBD e LD e LD e IL e ST e SFC Data Type e EDT e EDT e DDT e only simple arrays Mode e Maintenance Mode e Safety Mode Restart Behavior
105. k without MC protective Protective BISK Necessary minimum isk reduction Actual isk reduction San n MO Partial isk Partial risk covered by covered by Measurement and control MC protective ron MC f measures protective measures RTC real time clock S Safety Function function to be implemented by an E E PE safety related system other technology safety related system or external risk reduction facilities which is intended to achieve or maintain a safe state for the EUC in respect of a specific hazardous event Definition IEC 61508 166 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Glossary Safety Integrity probability of a safety related system satisfactorily performing the required safety functions under all the stated conditions within a stated period of time Definition IEC 61508 Safety PLC Quantum Safety PLC 140 CPU 651 608 or 140 CPU 671 60S Safety variable variable used to implement a Safety Function in a Safety Related System Safety Related System This term designates a system that both e implements the required Safety Functions necessary to achieve or maintain a Safe state for the EUC and e isintended to achieve on its own or using other E E PE Safety Related Systems other technology Safety Related Systems or external risk reduction facilities the necessary Safety Integrity for the required Safety Functions SF
106. le logic controllers PLCs For programming the Unity Pro XLS programming software of Schneider Electric must be used Unity Pro XLS provides all the functionality of Unity Pro XL and is additionally able to program the Quantum Safety PLC For further information on the differences between these software packages see Differences between standard and Safety Quantum PLC see page 25 IEC 61508 Description The IEC 61508 is a technical standard concerning the Functional Safety of electrical electronic or programmable electronic Safety Related Systems A Safety Related System is a system that is required to perform 1 or more specific functions to ensure risks are kept at an acceptable level Such functions are defined as Safety Functions A system is defined functionally Safe if random systematic and common cause failures do not lead to malfunctioning of the system and do not result in injury or death of humans spills to the environment and loss of equipment and production Description of the Safety Integrity Level SIL Safety Functions are executed to achieve and maintain the Safe state of a system The IEC 61508 specifies 4 levels of Safety performance for a Safety Function These are called Safety Integrity Levels SIL ranging from 1 the lowest to 4 the highest The Quantum Safety PLC is certified for use in SIL3 applications in which the de energized state is the Safe state for example in an emergency shutdown ESD system
107. lications Introduction Remark Schneider Electric offers you a number of elementary functions EF and function blocks EFBs that are certified for use in SIL3 applications For details see the Unity Pro Safety Block Library FFBs that are available for different data types are labeled with For example the elementary function S AND is available for the data type e BOOL AS S ANI BYTE aS S5 ANI D BOOL D BYTE h D WOR e e WORD as S AN e DWORD as S AND DWORD D Description of the Safety FFBs for Mathematics The following table lists the Safety FFBs belonging to the family of mathematical functions Name Type Used S_ADD_ EF to add the input values S_SUB_ EF to subtract the input 2 from the input 1 value S_MUL_ EF to multiply the input value S_DIV_ EF to divide the Dividend input value by the Divisor input value S_NEG_ EF to negate the input values S ABS EF to compute the absolute value of the input value S SIGN EF to detect negative signs S SMOVE BIT EFB to assign the input value to the output to use data from S SMOVE WORD unrestricted memory area in the Safety logic 33003879 01 2010 79 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Description of the Safety FFBs for Comparison The following table lists the Safety FFBs belonging
108. llow the requirements of the IEC 61508 Failure to follow these instructions will result in death or serious injury 118 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Special Requirements for Application Standards 5 Special Requirements for Application Standards Fire and Gas Systems Fire and gas systems should be integrated in accordance with EN 54 Fire and gas applications must operate continuously to provide protection As a result the following industry guidelines apply e f inputs and outputs are energized to mitigate a problem the PLC system must detect open and short circuits in the wiring between the PLC and the field devices and must raise alarms e Theentire PLC system must have redundant power supplies Further the power supplies that are required to activate critical outputs and to read Safety critical inputs must be redundant All power supplies must be monitored for proper operation e De energized outputs may be used for normal operation To initiate the actions to mitigate a problem the outputs are energized This type of system shall monitor the critical output circuits to help ensure that they are properly connected to the end devices Emergency Shutdown Systems In Emergency Shutdown systems the Safe state of the plant is a de energized or low 0 state 33003879 01 2010 119 This document provided by Barr Thorp Electric Co
109. mbol State Access Safety S10 input output Normally at 1 this is set to O when an I O fault on an in 1 no yes IOERR fault rack module or device on Fipio is detected e g non compliant configuration exchange fault hardware fault etc The S10 bit is reset to 1 by the system as Soon as the fault disappears 96811 watchdog Normally at 0 this is set to 1 by the system as soon as 0 no yes WDG overflow the task execution time becomes greater than the maximum execution time i e the watchdog declared in the task properties 969812 PLC in This bit is set to 1 by the system when the PLC is in 0 no yes PLCRUNNING RUN RUN It is set to 0 by the system as soon as the PLC is no longer in RUN STOP INIT etc 96813 first cycle Normally set to O this is set to 1 by the system during no yes 1RSTSCANRUN after the first cycle of the master task after the PLC is set to switching to RUN RUN A WARNING UNINTENDED EQUIPMENT OPERATION On Quantum Safety PLCs communication interruptions from NOE CRA or CRP modules are not reported on bit 96810 Make certain that these system bits are used correctly Failure to follow these instructions can result in death serious injury or equipment damage 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 135 System Objects Description of the System Bits S15 to S21 Detailed Description NOTE No
110. modules and their PFD PFH values for SIL3 applications Product Type Product Reference MTBF h PTI z 1 year PFDg PFHg Standalone Safety 140 CPU 651 60S 600 000 9 775E 06 4 723E 09 CPU Hot Standby Safety 140 CPU 671 60S 600 000 9 775E 06 4 723E 09 CPU Digital Input 140 SDI 953 00S 900 000 5 610E 07 1 867E 09 Digital Output 140 SDO 953 00S 1 000 000 7 155E 07 1 199E 09 Analog Input 140 SAI 940 00S 700 000 8 931E 07 1 424E 09 Power Supply PS 140 CPS 124 20 750 000 Product Type Product Reference PTI 5 years PFDg PFHg Standalone Safety 140 CPU 651 60S 4 913E 05 5 114E 09 CPU Hot Standby Safety 140 CPU 671 60S 4 913E 05 5 114E 09 CPU Digital Input 140 SDI 953 00S 2 805E 06 1 869E 09 Digital Output 140 SDO 953 00S 3 578E 06 1 200E 09 Analog Input 140 SAI 940 00S 4 466E 06 1 426E 09 Power Supply PS 140 CPS 124 20 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 17 Product Type Product Reference PTI 10 years PFDg PFHg Standalone Safety 140 CPU 651 60S 9 890E 05 5 601E 09 CPU Hot Standby Safety 140 CPU 671 60S 9 890E 05 5 601E 09 CPU Digital Input 140 SDI 953 00S 5 610E 06 1 872E 09 Digital Output 140 SDO 953 00S 7 156E 06 1 202E 09 Analog Input
111. n result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided can result in equipment damage PLEASE NOTE Electrical equipment should be installed operated serviced and maintained only by qualified personnel No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and the installation and has received safety training to recognize and avoid the hazards involved 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com About the Book A A na At a Glance Document Scope This Safety Reference Manual describes the Quantum Safety PLC with special regard to how it meets the Safety requirements of the IEC 61508 It provides detailed information on how to install run and maintain the system correctly in order to protect human beings as well as to prevent damage to environment equipment and production This documentation is intended for qualified personnel familiar with Functional Safety and Unity Pro Commissioning and operating the Quantum Safety PLC may only be performed by persons who are authorized to commission and operate systems in accordance with established Functional Safety standards
112. n STOP mode It is reset to 0 by the system before the following cycle 96S0 is not always set in the first scan of the PLC If a signal set for every start of the PLC is needed S21 should be used instead S1 warm see chapter System Bits see Unity Pro Program 0 no no WARMSTART restart Languages and Structure Reference Manual in the Unity Pro Program Languages and Structure Reference Manual 9684 time base see chapter System Bits see Unity Pro Program no no TB10MS 10 ms Languages and Structure Reference Manual in the Unity Pro Program Languages and Structure Reference Manual S5 time base see chapter System Bits see Unity Pro Program no no TB100MS 100 ms Languages and Structure Reference Manual in the Unity Pro Program Languages and Structure Reference Manual S6 time base see chapter System Bits see Unity Pro Program no no TB1SEC 1s Languages and Structure Reference Manual in the Unity Pro Program Languages and Structure Reference Manual 9687 time base see chapter System Bits see Unity Pro Program no no TB1MIN 1 min Languages and Structure Reference Manual in the Unity Pro Program Languages and Structure Reference Manual 134 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Bit Function Description Initial Write Quant Sy
113. n its behavior compared to the standard Quantum PLC For details on cyclic and periodic execution see the chapter Application Program Structure see Unity Pro Program Languages and Structure Reference Manual in the Unity Pro Program Languages and Structure Reference Manual 26 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Memory Hot Standby Redundant I O The memories of the Quantum Safety CPUs are each divided into a Safety and an unrestricted part The Safety memory area is write protected and used for processing Safety Related data The unrestricted memory area is not write protected and used if it is necessary to get access to the Safety Functions Its values cannot be used directly but by using specific function blocks see Memory Area page 107 In slot A PCMCIA memory cards can be used in a Quantum Safety CPU in the same way as they can be used in a standard Quantum CPU These cards can be standard type application and file type or data and file type memory cards For details on this topic see the chapter High End CPU see Quantum with Unity Pro Hardware Reference Manual in the Quantum with Unity Pro Hardware Reference Manual In contrast slot B for data and file type memory cards is not allowed to be used because this data storage is not available for SIL3 projects A WARNING LOSS OF ABILITY TO PERFORM SAFETY FUNCTIONS Do not use slot B D
114. nance Override if you use the Maintenance Mode to modify Safety data You can find it on the TUV Rheinland Group website hitp Wwww tuvasi comy Failure to follow these instructions can result in death serious injury or equipment damage 33003879 01 2010 107 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 108 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Checklists Introduction For a system to perform Safety Functions installing and configuring programming commissioning and operating must meet the Safety requirements of the IEC 61508 To ensure that Safety aspects are observed Schneider Electric recommends that you use the following checklists However these lists are not exhaustive and you are fully responsible for observing all Safety requirements mentioned in the IEC 61508 as well as in this manual What s in this Chapter This chapter contains the following topics Topic Page Checklist for Configuring Safety Related Systems 110 Checklist for Programming SIL3 Applications 112 Checklist for I O Modules 114 Checklist for Operation Maintenance and Repair 116 33003879 01 2010 109 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Checklist for Configuring Safety Related Systems Introduction This list is not exhaustive and
115. nce the Quantum Safety PLC exits Safety Mode and enters Maintenance Mode you are fully responsible for ensuring the Safe state of your system Failure to follow these instructions can result in death serious injury or equipment damage You can find a detailed description of the Maintenance Mode in Maintenance Mode page 89 33003879 01 2010 23 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Diagnostics Introduction The Quantum Safety PLC provides additional internal diagnostics and system testing increasing the diagnostic coverage DC Survey of the Diagnostics The internal architecture of the Quantum Safety CPU e provides 2 shutdown paths and e allows double code generation and execution to detect e systematic faults in the code generation and execution and e random faults in the CPU and the RAM The double code execution is controlled by 2 different processors integrated into the CPU For further details see Standalone Safety CPU page 33 The internal architecture of the Quantum Safety I O modules e provides redundancy e detects systematic faults in the code execution and e random faults in the I O modules The communication between the CPU and the I O is designed as a black channel The protocol checks or manages detected errors such as detected transmission errors omissions insertions wrong order delays incorrect addresses and masquerade b
116. nging from 1 to 3 For a detailed procedure see the chapter Configuring I O Modules for Safety Projects in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics Diagnostics at Power Up At power up the I O modules perform an extended self test during about 30 seconds If these tests are unsuccessful the modules are not considered to be healthy and do not start The inputs and outputs are then set to O If the 24 VDC external power supply is not connected to the digital input or digital output modules the power up self tests do not take place and the modules does not start Runtime Diagnostics During runtime the I O modules perform self tests The input modules verify that they are able to read data from the sensors over the complete range The output modules perform pulse tests on their switches with a duration lower than 1 ms 33003879 01 2010 43 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Description of the General Over Voltage Diagnostics Because the electronics may not work up to the theoretical maximum output voltage of the power supplies the I O modules must supervise the backplane power supply voltage The following table describes the supervision of the power supply The power supply of Is monitored by the backplane which has a theoretical maximum output voltage of 18 5 V 2 over voltage supervisors that is 1 for each micro processor
117. nt byte STOPYEAR contains the code for the last stop e 1 change from RUN to STOP by the SW58 terminal or the dedicated input STOPDAY e 2 stop by watchdog PLC task or SFC overrun 4 power outage or memory card lock operation e 5 stop on hardware fault e 6 stop on software fault Details on the type of software fault are stored in SW125 SW59 adjustment of Contains 2 8 bit series to adjust the current date O yes yes ADJDATETIME current date The action is performed on the rising edge of the bit This word is enabled by bit S59 1 In the following illustration bits in the left column increment the value and bits in the right column decrement the value Zo Type of value Bits 0 8 Day of the week 1 9 Seconds 2 10 linutes 3 11 Hours 4 12 Days 5 13 Months 5 14 Years T 15 Genturies 33003879 01 2010 147 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Description of the System Words SW60 to SW127 Detailed Description NOTE Not all of the system words can be used in the Quantum Safety PLC The unusable system words are marked no in the Quant Safety column The following table gives a description of the system words SW60 to SW127 Word Symbol Function Description Initial State Write Quant Access Safety SW60 HSB_CMD Quantum Hot Standby command register Meaning of the different bits of the word
118. o meet the requirements of the IEC 61508 only certified software is allowed for programming SIL3 applications For this purpose Schneider Electric has developed the Safety version of the programming tool Unity Pro XLS XL Safety It is able to perform both fault diagnostics and project protection to an extent necessary for programming a SIL3 project NOTE When you create a new project with Unity Pro XLS the choice of the Quantum PLC type determines if a SIL3 or non Safety project is created SIL3 and Non Safety Applications Unity Pro XLS can be used to program both SIL3 and non Safety applications Thus no other programming software is necessary Only 1 version can be installed on your computer Your SIL3 project is stored in binary project files STU and in archive project files STA You cannot open these files with non Safety versions of Unity Pro Further you can only download your executable binary files APX into a Safety CPU For details see the chapter Services in Offline Mode see Unity Pro Operating Modes in the Unity Pro Operating Modes Manual Non Safety projects created by non Safety Unity Pro versions must be exported using the appropriate Unity Pro version and imported into Unity Pro XLS Description of the Project Protection Unity Pro XLS offers protection against unauthorized access concerning your SIL3 project and the Quantum Safety PLC as well as Unity Pro XLS itself Your SIL3 project and the Quantum Sa
119. ons concerning the warnings of the language analyzer e Variables not used e Multiple writing of variables e Parameters not assigned e Multiple use of FB instances e Overlapping of addresses A WARNING POSSIBLE LOSS OF THE ABILITY TO PERFORM SAFETY FUNCTIONS Switch on all warning options in the project settings and check the warnings to make sure that they are not critical and that the behavior is intended Failure to follow these instructions can result in death serious injury or equipment damage 33003879 01 2010 69 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Requirements for Monitoring Unity Pro XLS is the only programming software allowed to load or to modify your SIL3 project Other programming packages or HMIs may monitor both the state and functions of the Safety Related System but must not alter them Any other device is allowed to read data from the Safety PLC but writing to a Safety PLC is restricted see also Memory Area page 101 70 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Process Safety Time Description of the Process Safety Time The process Safety time PST is a critical measure of each process It is defined as the period between the occurrence of a failure in equipment under control EUC and the occurrence of a hazardous event if the Safety Function is not per
120. onsists of 8 isolated independent input channels Each input is acquired by 2 identical circuits Each micro processor drives its ADC through isolators to acquire the input value Further it drives each DAC and may set itto high impedance not interfering or low impedance forcing the input of the ADC during diagnostics The analog input module performs e ashortterm self test during normal cyclical acquisition to detect a discrepancy that could result from an internal fault e along term self test during diagnostic acquisition to verify the health of each channel Description of the Power Supply Supervision There is no power supply supervisor This function is checked during ADC diagnostics as both ADC and DAC provide values dependant on their power supply voltage value 46 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Safety Digital Input Module Architecture Wiring Information The following figure shows the architecture of the Quantum Safety Digital Input module Field side CPU side Backplane Diag Internal Diagnostics DID Digital Input Deserializer DIS Digital Input Serializer DPM Dual Port Memory Isol Electrical Isolation uP Micro Processor NOTE The Safety digital inputs are de energized to trip The Safe input state is the de energized state that means if the input state goes to de energized the Safety Function is executed Therefore
121. ors which are part of the Safety loop All of them are composed of 2 micro controller systems running the same program sharing the same information and checking each other periodically You can install these I O modules in the local backplane or in remote I O drops Description of the CPU I O Communication In general the Quantum Safety CPU masters all backplane exchanges whereas the other modules are slaves Between Safety CPU and Safety I Os data are exchanged through a dual port RAM located in the I O module For the communication between CPU and remote I Os RIOs you must use the following 2 non interfering modules e 140 CRP 932 00 RIO head adapter located in the local rack e 140 CRA 932 00 RIO drop adapter located in the RIO drop The communication protocol between the Safety I O and CPU secures their exchanges It allows both to check the correctness of received data and detect any failure of the transmitter or during the transmission Thus a safety loop may include any non interfering RIO adapters and backplane For details on this topic see Safety I O Modules Diagnostics see page 43 The Safety I O modules provide features for line monitoring see Safety I O Modules Diagnostics see page 43 and the Quantum with Unity Pro Discrete and Analog I O Reference Manual NOTE Use the red labels provided with the Quantum Safety IO modules to clearly indicate the Safety modules 33003879 01 2010 39 This document pro
122. ory area with S SMOVE function blocks page 101 O Check the range of WORD data of non Safety related data from Memory Area the unrestricted memory area by configuring the S_SMOVE_WORD page 101 O function block Do not use conditional execution of Safety logic sections Requirements for the Program Structure page 68 Do not use jumps to labels inside FBD and LD logic Requirements for Language O Elements page 68 112 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Checks Reference in Done Remarks this Manual Program the non Safety logic for non interfering I Os in separate Available Non sections Interfering Products page 19 Indicate the non Safety Related variables with an appropriate Memory Area naming convention and comment page 101 Make sure that inputs or outputs of non interfering I O modules are Description of not used for calculating Safety Related outputs the I O Modules O page 54 Do not monitor concurrently a huge amount of data in Requirements Unity Pro XLS leads to increase of scan time for Monitoring O page 70 In the project settings switch on all options for warnings during Checks for analysis Check all warnings and make sure that they are not Programming critical and that the behavior is intended page 69 33003879 01 2010 This document provided by Barr Thorp El
123. our Safety PLC and e downloaded your SIL3 project into the Safety PLC Starting the Quantum Safety PLC Once the Quantum Safety PLC contains a valid project it only performs cold start Therefore you can only start your SIL3 project by performing a cold start except when you have just downloaded your project into the PLC Hence you can start your project out of the following 2 initial states e The PLC is powered up and you have downloaded your SIL3 project since power up e The PLC is powered off Further Unity Pro XLS offers the Automatic start in Run option If it is activated your PLC automatically enters run state in Safety Mode after power up However Schneider Electric recommends not using this option 4 WARNING UNINTENDED EQUIPMENT OPERATION Avoid using the Automatic start in Run option If you use this feature it is your responsibility to program and configure the system in such a way that it behaves correctly after restart Failure to follow these instructions can result in death serious injury or equipment damage You can find detailed procedures for starting a SIL3 project in the chapter Starting and Stopping a Safety Project see Unity Pro XLS Software Operating Mode Manual Safety PLC Specifics in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics 33003879 01 2010 95 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Version St
124. ous injury or equipment damage 33003879 01 2010 57 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Content of the System Words SW125 contains the cause of the detected error and have the following meaning Code hex Meaning Ox5AF1 sequence check detected error unpredictable execution in CPU Ox5AF2 detected error in memory incorrect address Ox5AF3 detected comparison error result of the execution of the Intel processor differs from that of the application processor Ox5AF4 real time clock detected error Ox5AF5 detected error initializing double code execution Ox5AF6 detected watchdog activation error Ox5AF7 detected error during memory check it takes more than 8 hours Ox5AF8 detected error in memory check in RAM SW126 and SW127 contain information that is for Schneider Electric internal use to analyze the problem in more detail 58 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Improper Behavior of the Safety I O Modules General The Safety I O modules detect an internal error in either e a channel e the complete module Detected Channel Error If an error is detected in a channel this channel is set to the Safe state while the other channels continue to operate The information about the detected error is available in the status registers of th
125. owing figure shows an example of a Quantum Safety PLC consisting of redundant CPUs and redundant I Os HSBYlink The following figure provides the appropriate functional overview Actuator Primary NOTE Schneider Electric recommends always placing redundant Safety I O modules in different RIO drops 64 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Programming Introduction This chapter deals with the topics important for programming your SIL3 project The requirements for programming a Safety Related System are described and the SIL3 features are explained What s in this Chapter This chapter contains the following sections Section Topic Page 3 1 General Information on Programming 66 3 2 Software Description 76 3 3 Operating Procedures 84 3 4 Special Features and Procedures 93 3 5 Communication 100 33003879 01 2010 65 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 3 1 General Information on Programming Introduction This section provides general information on programming a SIL3 application with regard to programming and monitoring requirements What s in this Section This section contains the following topics Topic Page Available Language Sections 67 Exceptions and Requirements for Programming 68 Process Safety Time 71 66
126. page 39 All standard components of Schneider Electric for wiring remote I Os cables connectors and so on are allowed to be used in the Safety Related System Description of the Ethernet Module The Ethernet module 140 NOE 771 11 can be used for the communication of the Safety PLC with other PLCs HMls or I Os on the Ethernet network It does not alter Safety Related data and therefore is not part of the Safety loop For detailed information on this topic see PLC PLC Communication page 105 The Ethernet module can only be configured in the local rack 33003879 01 2010 53 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Description of the Backplanes The backplanes 140 XBP 016 00 140 XBP 010 00 and 140 XBP 006 00 are the equipment on which you can mount all Safety and non interfering modules NOTE Backplane expanders are not allowed in the Quantum Safety PLC Description of the I O Modules You are allowed to configure non interfering I O modules in your Safety PLC However they must not be part of the Safety loop A CAUTION INCORRECT USE OF SAFETY RELATED DATA Make sure that neither inputs nor outputs of non interfering I O modules are used for calculating Safety Related outputs These modules are only allowed to process non Safety signals The logic used to process the non interfering I Os must follow the same rules as for Safety logic The non interfering I Os must b
127. raining Contents In addition to the usual training courses concerning the use of the company s products Schneider Electric offers you training courses covering the topics of its IEC 61508 compliant Safety Related System 28 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 1 2 Safety Requirements Requirements for Hardware and Programming Introduction You must fulfill the following Safety requirements when using the Quantum Safety PLC Hardware Requirements e Fora SIL project you must use 1 of the 2 following Quantum Safety CPUs e 140 CPU 651 60S for stand alone systems e 140 CPU 671 60S for systems requiring high availability e Only Quantum Safety modules are allowed to perform Safety Functions Non interfering modules can be part of the Safety PLC because they do not interfere with the Safety modules by their own means However they are not allowed to execute Safety Functions They can only be used to process non Safety signals except the backplanes and remote IO adapters which are considered as part of a black channel e The Safe state of the outputs is the de energized state e You must follow the specified operating conditions regarding EMC mechanical and climatic influences For details see the chapter System Specifications in the Quantum with Unity Pro Hardware Reference Manual NOTE Backplane expanders and distributed I Os are not allowed in
128. re illustrates the redundant analog input configuration aero The function block S_ATSIL2 see also Functions Function Blocks for SIL3 Applications page 79 can be used for selecting the data from the 2 redundant analog inputs and to supervise the state of the inputs 40 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com High Availability Digital Input Modules The redundant Safety digital inputs can be connected to either 1 or 2 sensors The 2 input points must be located on different input modules In case you use 1 sensor the modules share the same process power supply Using the information on the modules input characteristics on short circuit open wire zero and one level voltage and current specified in the Quantum with Unity Pro Discrete and Analog I O Reference Manual you must define the wiring to fulfill these characteristics The following figure illustrates the redundant digital input configurations za HU The function block S DISILS3 see also Functions Function Blocks for SIL3 Applications page 79 can be used for selecting the data from the 2 redundant digital inputs and to supervise the state of the inputs 33003879 01 2010 41 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com High Availability Digital Output Modules For high availability digital outputs the 2 outputs must
129. reating or modifying the application password e entering Maintenance Mode or e adapting the auto lock timeout For details of using the Security Editor see also the chapter Access Security Managment see Unity Pro Operating Modes in the Unity Pro Operating Modes Manual and the chapter Security Management for Unity Pro XLS in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics NOTE Use the features provided by the Security Editor to protect Unity Pro XLS against unauthorized access However using the Security Editor does not remove the necessity to protect your SIL3 project by using an application password Description of the Auto Lock Feature Unity Pro XLS offers the option to protect itself against unauthorized access after a configured time of inactivity After this time is exceeded Unity Pro XLS prompts you to enter the application password You can find a detailed procedure for activating the auto lock in the chapter Protection of a Safety Project with Unity Pro XLS in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics Default Values When you create a new SIL3 project the following values are set by default e The application password is empty e The auto lock is activated allowing 10 minutes of inactivity before Unity Pro XLS is locked 78 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Functions Function Blocks for SIL3 App
130. ric Co Inc 800 473 9123 www barr thorp com Index H HALTIFERROR 740 hardware catalog 94 hardware fault tolerance HFT 127 HFT hardware fault tolerance 127 Hot Standby HSBY 15 automatic swap 27 Maintenance Mode 36 run offline 36 run primary state 36 run standby state 36 Safety Mode 36 stop offline 36 HOURMIN 146 HSB_CMD 148 HSB_STS 149 HSBY Hot Standby automatic swap 27 Maintenance Mode 36 run offline 36 run primary state 36 run standby state 36 Safety Mode 36 stop offline 36 HSBY REVERSEi 150 IEC 61508 Emergency Shutdown ESD 15 ESD Emergency Shutdown 15 Functional Safety 124 Safe state 15 Safety Integrity Level SIL 15 SIL Safety Integrity Level 15 IEC 61511 Functional Safety for the process indus try 124 IEC61508 Functional Safety 15 INDEXOVF 137 installation Unity Pro XLS 77 INTELMODE 143 IOERR 135 IOERRTSK 136 IOEVTNB 145 K KEY SWITCH 150 L LOCIOERR 140 Maintenance Mode 23 89 Debug Mode 90 halt state 90 run state 90 MASTACT 138 MASTCURRTIME 145 MASTMAXTIME 145 MASTMINTIME 145 MASTPERIOD 142 MAXREQNB 157 mean time between failures MTBF 730 MONTHDAY 146 MSGONTO 151 MSGCNT1 151 MSTSERVONT 151 MTBF mean time between failures 130 O OSCOMMPATCH 143 OSCOMMVERS 143 OSINTVERS 143 OVERFLOW 136 OVERRUN 136 P PCMCIABATO 139 PCMCIABAT1 139 PFD probability of failure on demand 17 20 PFD proba
131. rite data to the Safety memory area from other devices Communication PLCs HMI and so on page 100 Do not download the Ethernet processor firmware while the PLC is Safety Mode running in Safety Mode Restrictions page 87 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 111 Checklist for Programming SIL3 Applications Introduction This list is not exhaustive and you are fully responsible for observing all Safety requirements mentioned in the IEC 61508 as well as in this manual Configure the maximum unrestricted areas for M and MW Description of Checklist Schneider Electric recommends that you use the following checklist for programming your SIL3 application Checks Reference in Done Remarks this Manual Check the consistency of Unity Pro XLS regularly Checking the Programming L Environment page 94 Check the correctness of your project Programming Requirements O page 30 Test and verify the complete logic as part of the commissioning go Configure the maximum M and MW correctly Memory Area page 101 O correctly the Maximum CPU Cycle Time page 73 Check that the configured maximum UMA for M and MW is Memory Area downloaded correctly check with SW110 and SW111 page 101 O Check the correct usage of non Safety related data from the Memory Area unrestricted mem
132. s originally installed and are not corrupted for instance by hard disk corruption The self test is done by evaluating the CRC Description of the Self Test When performing the self test Unity Pro XLS checks the version and CRC of e DLLs of Unity Pro XLS e the Safety FFB library database and e the hardware catalog database A WARNING RISK OF CORRUPTED PROGRAM Use the self test of Unity Pro XLS on a regular basis to check the integrity of your program At least perform the self test e after installing any software on or removing it from your computer e before loading the final operating program into the Safety PLC e before modifying a program in the running Safety PLC Failure to follow these instructions can result in death serious injury or equipment damage You can find details of how to start the self test in the chapter Unity Pro XLS Self Test see Unity Pro XLS Software Operating Mode Manual Safety PLC Specifics in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics 94 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Starting the Quantum Safety PLC Preconditions Preconditions to start the Quantum Safety PLC are that you have e configured your Safety Related System correctly e programmed your SIL3 project correctly e tested the integrity of both your SIL3 project and Unity Pro XLS e connected Unity Pro XLS to y
133. s the relation between SFF HFT and SIL for complex Safety Related subsystems according to IEC 61508 2 in which the failure modes of all components cannot be completely defined SFF HFT 0 HFT 1 HFT 2 SFF lt 60 SIL1 SIL2 60 SFF x 90 SIL1 SIL2 SILS 90 SFF x 99 SIL2 SIL3 SIL4 SFF gt 99 SIL3 SIL4 SIL4 There are 2 ways to reach a certain Safety Integrity Level e via increasing the HFT by providing additional independent shutdown paths e via increasing the SFF by additional diagnostics SIL Demand Relation Description The IEC 61508 distinguishes between low demand mode and high demand or continuous mode of operation In low demand mode the frequency of demand for operation made on a Safety Related System is not greater than 1 per year and not greater than twice the proof test frequency The SIL value for a low demand Safety Related System is related directly to its average probability of failure to perform its Safety Function on demand or simply probability of failure on demand PFD In high demand or continuous mode the frequency of demand for operation made on a Safety Related System is greater than 1 per year and greater than twice the proof test frequency The SIL value for a high demand Safety Related System is related directly to its probability of a dangerous failure occurring per hour or simply probability of failure per hour PFH 33003879 01 2010 127 This document pro
134. si Input CPU Out put di 7 i iii 354 50 of PFH of PFH PLC 15 of PFH of Safety bop As shown in the figure above the contribution of the PLC is only 10 2096 because the probability of failure of sensors and actuators is usually quite high A conservative assumption of 10 for the Safety PLC s contribution to the overall probability leaves more margin for the user and results in the following required probabilities of failure for the Safety PLC e PFD 2 10 to lt 10 for low demand e PFH gt 10 to lt 10 for high demand 33003879 01 2010 129 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com PFD Equation Description The IEC 61508 assumes that half of the failures end in a Safe state Therefore the failure rate is divided into e g the safe failure and e Ap the dangerous failure itself composed of e App dangerous failure detected by the internal diagnostic e Apy dangerous failure undetected The failure rate can be calculated by using the mean time between failures MTBF a module specific value as follows 1 MTBF The equation for calculating the probability of failure on demand is PFD t Apu xt t represents the time between 2 proof tests The probability of failure per hour implies a time interval of 1 hour Therefore the PFD equation is reduced to the following one PFH Apy 130 33003879 01 2010 This document provided by Barr Thorp
135. stem words are marked in the Quant Safety column with no The following table gives a description of the system words SW30 to SW59 Word Function Description Initial Write Quant Symbol State Access Safety SW30 master task This word indicates the execution time of the last no no MASTCURRTIME execution time master task cycle in ms 9eSW31 maximum This word indicates the longest master task no yes MASTMAXTIME master task execution time since the last cold start in ms execution time SW32 minimum This word indicates the shortest master task no yes MASTMINTIME master task execution time since the last cold start in ms execution time SW33 fast task see chapter System Objects see Unity Pro no no SW34 execution Program Languages and Structure Reference SW35 times Manual in the Unity Pro Program Languages and Structure Reference Manual SW36 to auxiliary tasks see chapter System Objects see Unity Pro no no SW47 execution Program Languages and Structure Reference times Manual in the Unity Pro Program Languages and Structure Reference Manual SW48 number of see chapter System Objects see Unity Pro 0 yes no IOEVTNB events Program Languages and Structure Reference Manual in the Unity Pro Program Languages and Structure Reference Manual 33003879 01 2010 145 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com
136. t all of the system bits can be used in the Quantum Safety PLC The unusable system bits are marked in the Quant Safety column with no The following table gives a description of the system bits 96515 to 96821 Bit Function Description Initial Write Quant Symbol State Access Safety 969815 character see chapter System Bits in the Unity Pro Program 0 yes no STRINGERROR string fault Languages and Structure Reference Manual 96816 task Normally set to 1 this bit is set to 0 by the system when 1 yes yes IOERRTSK input output a fault occurs on an in rack I O module or a Fipio device fault configured in the task This bit must be reset to 1 by the user 96917 rotate or normally at O 0 no yes CARRY shift output During a rotate or shift operation this bit takes the state of the outgoing bit 96818 overflow or Normally set to 0 this bit is set to 1 in the event of a 0 yes yes OVERFLOW arithmetic capacity overflow if there is error e aresult greater than 32 767 or less than 32 768 in single length e result greater than 65 535 in unsigned integer e aresult greater than 2 147 483 647 or less than 2 147 483 648 in double length e result greater than 4 294 967 296 in double length or unsigned integer e real values outside limits e division by O e the root of a negative number e forcing to a non existent step on a drum e stacking up of an already full register
137. t also to have access to the software required to read them NOTE Choose the backup policy that is the most appropriate for your Safety Related System Make the adequate amounts and types of backups Test frequently the process for restoring the original project from the backup copies 98 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Detected Faults Introduction If a fault is detected by any of the internal diagnostic measures and system tests the behavior of the Quantum Safety PLC varies according to the mode that it is in Fault Behavior in Safety Mode Running in Safety Mode your PLC enters error state in case of a single detected fault because it has no means to recover from it The error state is a hardware locked state Your project is stopped and you cannot intervene or communicate with it Leaving the Error State The only way to leave the error state is to start your PLC again whereupon the PLC performs self tests and initializes your project If your project Then your PLC is valid enters stop state which it is forced to do because of the detected fault is invalid enters no conf state NOTE The PLC may be in an error state if the persistent detection of an error occurs In this case it may be necessary to replace the PLC Depending on the state which your PLC is in perform the following steps If your proje
138. the Quantum Safety PLC configuration NOTE All Safety and non interfering modules fulfill the requirements of the IEC 61131 2 33003879 01 2010 29 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Programming Requirements e For programming a SIL3 project you must use the certified Quantum Safety firmware and the Safety programming software Unity Pro XLS e You must make sure that your SIL3 project is configured and programmed correctly according to the rules of the IEC 61508 as well as to the rules described in this Safety Reference Manual e Forthe complete life cycle of the project development you must follow the requirements of the IEC 61511 for installation commissioning and validation e Thelogic can be tested in simulation mode butthe full test of the Safety Functions must be performed with the runtime system and the complete installation A WARNING RISK OF PROJECT ERRORS Check that your project is correct according to your specification by performing tests on the runtime system Failure to follow these instructions can result in death serious injury or equipment damage Proof Test Procedure The user must perform the proof test procedure periodically see IEC61508 4 3 8 5 The maximum time between 2 proof test is the proof test interval For the safety PLC itself the proof test consists of e A power cycle e Checks that all modules restart without a d
139. the tests the CPU enters an error state and all Safety related outputs go to the Safe state Handling Detected Errors If a an error is detected perform the following steps Step Action 1 Power off the complete PLC 2 Switch the power on again Result A self test is performed 3 Read the content of the system words SW125 SW126 and SW127 for information on the detected error state see Description of the System Words SWEO to SW127 page 148 4 Provide the contents of these system words and Unity Pro project system words to Schneider Electric support Some of the detected errors are temporary and disappear after a restart of the PLC Others require replacement of the CPU NOTE If an Automatic Start in Run option for the CPU is configured its use is not recommended in a Safety PLC and if the diagnostic error is persistent the CPU again enters the error state and stops To read the values of the system words prevent a restart by either e removing the PCMCIA memory card the application is stored on the card e by inserting an empty PCMCIA memory card the application is stored in memory 4 WARNING UNINTENDED EQUIPMENT OPERATION Avoid using the Automatic start in Run option If you use this feature it is your responsibility to program and configure the system in such a way that it behaves correctly after restart Failure to follow these instructions can result in death seri
140. to a BYTE WORD DWORD INT DINT UINT Or UDINT data type S BYTE TO EF BYTE to a BOOL WORD DWORD INT DINT UINT Or UDINT data type S WORD TO EF WORD to a BOOL BYTE DWORD INT DINT UINT Or UDINT data type S DWORD TO EF DWORD to a BOOL BYTE WORD INT DINT UINT or UDINT data type S INT TO EF INT to a BOOL BYTE WORD DWORD DINT UINT Of UDINT data type S DINT TO EF DINT to a BOOL BYTE WORD DWORD INT UINT Or UDINT data type S UINT TO EF UINT to a BOOL BYTE WORD DWORD INT DINT Or UDINT data type S UDINT TO EF UDINT to a BOOL BYTE WORD DWORD INT DINT Or UINT data type Description of the Safety FFBs for High Availability The following table lists the Safety FFBs belonging to the family of functions for high availability Name Type Used S DISIL2 EFB to select the data from the 2 digital input modules in case of a redundant input module configuration S AISIL2 EFB to select the data from the 2 analog input modules in case of a redundant input module configuration Description of the Safety FFBs for Hot Standby The following table lists the Safety FFBs belonging to the family of functions for Hot Standby Name Type Used S_HSBY_SWAP EFB to swap between primary and standby CPU in case of a Hot Standby solution Details of how to use the Safety FFBs in your project you can find in the Unity Pro Safety Block L
141. to the family of comparison functions Name Type Used to check the values of successive inputs S EQ EF for equality S GT EF for a decreasing sequence S GE EF for a decreasing sequence or equality S LT EF for an increasing sequence S LE EF for an increasing sequence or equality S NE EF for inequality Description of the Safety FFBs for Logic The following table lists the Safety FFBs belonging to the family of logic functions Name Type Used S_AND_ EF to perform a bit by bit AND link of the input bit sequence S OR EF to perform a bit OR link of the input bit sequence S XOR EF to perform a bit XOR link of the input bit sequence S NOT EF to negate the input sequence bit by bit S SHL EF to shift a bit pattern to the left S SHR EF to shift a bit pattern to the right S ROL EF to rotate a bit pattern circularly to the left S ROR EF to rotate a bit pattern circularly to the right S_RS EFB as RS memory with a dominant reset input S_SR EFB as SR memory with a dominant set input S_F_TRIG EFB to detect falling edges S R TRIG EFB to detect rising edges 80 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Description of the Safety FFBs for Statistics The following table lists the Safety FFBs belonging to the family o
142. tric approved software Failure to follow these instructions can result in death serious injury or equipment damage A WARNING UNINTENDED EQUIPMENT OPERATION e Referto IEC 61508 Functional safety of electrical electronic programmable electronic safety related systems e Completely understand the applications and environment defined by Safety Integrity Level SIL 3 within IEC 61508 Parts 1 7 First edition e SIL requirements are based on the standards current at the time of certification Do Not exceed SIL3 ratings in the application of this product e Theterms identified in the list below as used in this document are applied only within the SILS rating Failure to follow these instructions can result in death serious injury or equipment damage 33003879 01 2010 11 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Terms used in this document certified fault non interfering Quantum Safety PLC Quantum Safety CPU Safety analog inputs Safety analog module s Safety CPU Safety digital inputs Safety digital modules Safety digital outputs Safety FFB Safety firmware Safety I O module s Safety library Safety logic Safety memory area Safety modules Safety mode Safety outputs Safety PLC Safety power supply Safety programming Safety Quantum Safety Related application s Safety remote I O Safety variable User Comments failure except
143. u must consider the following relation between the maximum timeout Tour for the output modules and the maximum CPU cycle time Tout gt 4 x max CPU cycle time worst case 74 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Configuring the Maximum CPU Cycle Time The Quantum Safety PLC can perform cyclic or periodic execution There is no difference between the behavior of a standard Quantum PLC and a Quantum Safety PLC regarding cyclic and periodic execution In both cases you must configure the maximum acceptable CPU cycle time in Unity Pro XLS The maximum allowed CPU cycle time watchdog is configured in the properties of the MAST task For details see the chapter Programming in the Unity Pro Operating Modes Manual and the chapter Presentation of the Master Task in the Unity Pro Program Languages and Structure Reference Manual NOTE The minimum CPU cycle time is 20 ms NOTE Only configure a maximum number of M and MW that is really needed All configured memory ranges M and MW are compared as part of the double execution which takes roughly 5 5 ms per 10 000 words Therefore you increase the cycle time unnecessarily if you configure more memory than needed You must check your CPU cycle time when commissioning your project At this time Unity Pro XLS provides the real time values from the PLC You can find this information e in the Task tab available
144. uch as application exception power on off and so on The functions available in Unity Pro XLS depend on the operating mode Switching between the modes requires defined conditions and follows certain procedures For details see the chapter Switching Between Safety and Maintenance Mode see Unity Pro XLS Software Operating Mode Manual Safety PLC Specifics in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics You can interact with the Safety PLC using e the programming tool Unity Pro XLS e the keypad of the Quantum Safety CPU e the key switch Depending on the operating mode the Safety PLC can be in different states After power up it automatically enters run state of the Safety Mode if the following 2 conditions are fulfilled e There is a valid application e The Automatic start in Run option is activated In case of an invalid application it enters the not configured no conf state of the Maintenance Mode only if the key state is unlocked in which you are able to download your project If a fault is detected the PLC enters e halt state when running in Maintenance Mode e error state when running in Safety Mode 33003879 01 2010 85 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com PLC States The following figure shows the state diagram of the Quantum Safety PLC Power ON Y Valid application Invalid application
145. use this feature it is your responsibility to program and configure the system in such a way that it behaves correctly after restart Failure to follow these instructions can result in death serious injury or equipment damage 88 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Maintenance Mode Maintenance Mode Description The Maintenance Mode of the Quantum Safety PLC is a temporary mode for modifying your project and debugging and maintaining your program Maintenance Mode Features This mode is available in both RUN and STOP The PLC allows direct transition from RUN SAFE to RUN MAINTENANCE and RUN MAINTENANCE to RUN SAFE The Maintenance Mode protected by a password allow users to perform e online modifications programs enhancements temporary modifications etc e forcing values for sensor or actuator maintenance e system installation and commissioning When the PLC is running in Maintenance Mode the following features are implemented by Unity Pro XLS e Download changes are allowed e Setting and forcing of Safety variables and Safety I Os is allowed However only variables of the type EBOOL can be forced e Switching to Safety Mode while forcing is allowed The forced variables stay forced see also Forcing page 91 e Debugging with breakpoints watch points and single step is allowed However the PLC must be in run state e
146. using the menu entry Tools PLC Screen e in SW30 containing the current time of the MAST task execution e in SW31 containing the maximum time of the MAST task execution e in SW32 containing the minimum time of the MAST task execution For details see Description of the System Words SW30 to SW59 page 145 or the chapter Description of the System Words SW30 to SW47 in the Unity Pro Program Languages and Structure Reference Manual f your maximum acceptable CPU cycle time is exceeded you must adjust your configuration or your user logic or both to reach the required value A WARNING RISK OF EXCEEDING THE PROCESS SAFETY TIME Set the maximum CPU cycle time taking into account your process Safety time Failure to follow these instructions can result in death serious injury or equipment damage 33003879 01 2010 75 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 3 2 Software Description Introduction This section describes the special characteristics of Unity Pro XLS developed to program SIL3 applications What s in this Section This section contains the following topics Topic Page Unity Pro XLS 77 Functions Function Blocks for SIL3 Applications 79 Application Password 83 76 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Unity Pro XLS Introduction T
147. ut state 51 TIMEREVTNB 150 TSKINHIBIN 142 TSKINHIBOUT 142 TSKINIT 142 U UMA unrestricted memory area 101 Unity Pro OSLoader 22 Unity Pro XLS installation 77 self test 94 unrestricted memory area 101 unrestricted memory area UMA 101 V version stamp 96 176 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Index W warm start 25 WARMSTART 134 watchdog 34 WDG 135 WDGVALUE 142 WEEKOFYEAR 150 write protection 101 Y YEAR 146 33003879 01 2010 177 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Index 178 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com
148. uted I Os which communicate via Modbus Plus are not allowed in the Quantum Safety PLC Unity Pro XLS checks that no distributed I Os are configured If you do not obey this rule the Unity Pro analyzer does not generate code e Os communicating via other fieldbuses are not allowed in the Quantum Safety PLC Unity Pro XLS checks that no fieldbus I Os are configured If you do not obey this rule the Unity Pro analyzer creates a relevant error message and does not generate code 33003879 01 2010 55 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 2 6 System Behavior in Case of Detected Diagnostic Errors Introduction The Safety CPU modules and the Safety I O modules have internal diagnostics to check if the modules are working correctly This chapter describes the behavior of the modules in case an error is detected Also your possibilities to intervene are explained What s in this Section This section contains the following topics Topic Page Improper Behavior of the Safety CPU Modules 57 Improper Behavior of the Safety I O Modules 59 56 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Improper Behavior of the Safety CPU Modules General The CPU diagnostics verifies the correctness of the hardware and the running program see Standalone Safety CPU page 33 If an error is detected during 1 of
149. verification protocol for example send a word and its complement and then check the consistency in the application copy the word in a new location and then reread the value etc Write Protection Description Unity Pro XLS checks at edition time and at build time that only variables from the unrestricted memory area are used as input to the Safety MOVE function blocks In addition Unity Pro XLS provides a cross reference feature to search for the variable usage enabling you to check the rule easily A WARNING RISK OF PROCESSING INCORRECT DATA Make sure that the data you move to the Safety memory area are correct data Data transferred to the Safety memory area using the Safety MOVE function blocks are not automatically correct Failure to follow these instructions can result in death serious injury or equipment damage To help ensure that data are transferred accurately you can write the data to 2 different variables and then compare them 33003879 01 2010 103 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com PC PLC Communication Introduction Once you have programmed your SIL3 project you must connect Unity Pro XLS to the Quantum Safety PLC if you want to download run and maintain it To enable the communication between both you can connect Unity Pro XLS to the following Modbus TCP either with CPU or NOE module Modbus Plus Modbus RS232 RS485
150. vided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com SILs for Low Demand The following table lists the requirements for a system in low demand mode of operation Safety Integrity Level Probability of Failure on Demand 4 S107 to lt 104 3 gt 10 to lt 10 2 gt 10 to lt 10 1 gt 10 to 107 SILs for High Demand The following table lists the requirements for a system in high demand mode of operation Safety Integrity Level Probability of Failure per Hour 4 gt 10 to lt 10 3 10 to lt 107 107 to 10 1 108 to lt 10 For SIL3 the required probabilities of failure for the complete Safety integrated system are e PFD gt 10 to lt 10 for low demand e PFH gt 10 to lt 107 for high demand 128 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Safety Loop Description The Safety loop to which the Quantum Safety PLC consists of the following 3 parts e Sensors e Quantum Safety PLC with Safety CPU and Safety I O modules e Actuators A backplane or a remote connection with CRA CRP do not destroy a Safety Loop Backplanes CRP and CRA modules are part of a black channel This means that the data exchanged by I O and PLC cannot be corrupted without detection by the receiver The following figure shows a typical Safety loop SAFETY LOOP i Sen
151. vided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Safety Digital Output Module Architecture The following figure shows the architecture of the Quantum Safety Digital Output module Backplane Diag Internal Diagnostics DOD Digital Output De serialize DOS Digital Output Serializer DPM Dual Port Memory Isol Electrical Isolation uP Micro Processor 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com 49 Wiring Information You should protect the field power supply of the Safety digital output modules by a fuse This fuse protects the module not only against reversed field power supply but also against field power supply overvoltage There must not be any current limitation and the field power supply must be able to deliver 50 A during 0 2 s in case of short circuit The fuse must be chosen according to the driven load and must not exceed 16 0 5 1 25 10 A fast blow IEC 61131 2 Thus you should use a fast 10 A fuse on the field power supply input of each digital output module A WARNING SHORT CIRCUIT RISK Use a 10 A 250 V fast blow fuse to protect the field power supply against reversed power and over voltage Failure to follow these instructions can result in death serious injury or equipment damage The ground of the field power supply must be wired to the terminal block of the output module separately from
152. vided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Safety I O Modules in High Availability Configurations Introduction The Quantum Safety I O modules can be used in a redundant way to increase the availability However using redundant Safety modules does not increase Safety Schneider Electric provides function blocks to supervise the state for a configuration with 2 redundant modules The health of the modules is available by system words which you can evaluate and make available to the operator and maintenance personnel in order to inform them in case a module is inoperable and must be exchanged Each bit in the word represents the health of one channel For further details see the chapter Quantum Safety I O Modules in the Quantum with Unity Pro Discrete and Analog I O Reference Manual The system is still running in a SIL3 configuration and the only time limit for the exchange of the module is the proof test interval The modules can be placed in the same drop However Schneider Electric recommends using different drops to avoid problems in a single drop remote adapter or power supply outage see also chapter Configuration Examples for the Quantum Safety PLC page 60 High Availability Analog Input Modules 2 sensors must be used for high availability Safety analog inputs and each must be connected to a different input point The 2 input points must be located on different input modules The following figu
153. wed from the unrestricted memory area Unity Pro XLS checks this rule and creates an error if it is not obeyed Description of the Modbus Plus Communication The Modbus Plus module 140 NOM 2XX 00 is not allowed for communication You can only use the Modbus Plus port of the CPU On the Modbus Plus network a peer to peer communication or a global data exchange is possible Configuring the Modbus Plus Peer to Peer Communication The peer to peer communication is configured in Unity Pro XLS in the Modbus Plus network configuration independently for reading and writing Unity Pro XLS checks that reading uses only the unrestricted memory area It creates an error and does not generate code if this rule is not obeyed Configuring the Modbus Plus Global Data Communication The global data communication is configured in Unity Pro XLS in the Modbus Plus network configuration independently for reading and writing Unity Pro XLS checks that reading uses only the unrestricted memory area It creates an error and does not generate code if this rule is not obeyed A WARNING UNDETECTABLE LOSS OF DATA Do not write from an external device to the Safety memory area in the Quantum Safety PLC using Ethernet The data are ignored because of the Safety PLC s write protection The data are lost without you being notified Failure to follow these instructions can result in death serious injury or equipment damage 106 33003879 01 2010
154. word counts the number of forced I O O no yes FORCEDIOIM forced I O module bits This word is incremented for every module bits forcing and decremented for every unforcing SW110 number of This system word gives information on the size of no yes unrestricted the unrestricted memory area for M memory area This system word is not available for the standard for M Quantum CPU 9eSW111 number of This system word gives information on the size of no yes unrestricted the unrestricted memory area for MW memory area This system word is not available for the standard for MW Quantum CPU 33003879 01 2010 151 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Word Function Description Initial Write Quant Symbol State Access Safety SW124 type of system This system word is updated if the PLC is setto no yes CPUERR fault error state The possible values are as follows 0x0065 execution of HALT instruction impossible 0x0080 system watchdog If the PLC is set to Safety error state the content of SW125 is updated and can be read after the next restart of the PLC see below 152 33003879 01 2010 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com System Objects Word Symbol Function Description Initial State Write Access Quant Safety SW125
155. y CPU Specifics 20 20000 0 eee 35 22 Safety VO Modules sisesesa e a ERR EREERRREERSEGXW ences ES 38 General Information on the Safety I O Modules 39 Safety I O Modules in High Availability Configurations 40 Safety I O Modules Diagnostics 22 2c2cse0e0e eee ee nn 43 Safety Analog Input Module 2 20 eee ees 45 Safety Digital Input Module 0 002 c eee ee 47 Safety Digital Output Module 00 c eee ee 49 2 3 Power Supply uehementer eae eae Roa ode e Wee rm eS ae 52 Power Supply for the Quantum Safety PLC 0 0 52 2 4 Non Interfering Modules 000 cee eee ees 53 Non Interfering Modules for the Quantum Safety PLC 53 25 Restrictions on I O Modules 00 0c eee ees 55 Description of the Restrictions on I O Modules 00005 55 2 6 System Behavior in Case of Detected Diagnostic Errors 56 Improper Behavior of the Safety CPU Modules 57 Improper Behavior of the Safety I O Modules 59 2 7 Configuration Examples 20x OR E Rer e kes IRI ERES 60 Configuration Examples for the Quantum Safety PLC 60 33003879 01 2010 3 This document provided by Barr Thorp Electric Co Inc 800 473 9123 www barr thorp com Chapter 3 Programming llleleleeeeeeees 65 3 1 General Information on Programming
156. you are fully responsible for observing all Safety requirements mentioned in the IEC 61508 as well as in this manual Checklist Schneider Electric recommends that you use the following checklist for configuring your Safety Related System Checks Reference in Done Remarks this Manual Check and verify the PFD PFH values of the complete Safety loop Functional Safety LJ Certification page 16 Respect all rules described in the following reference manuals e Quantum with Unity Pro Hardware Reference Manual O e Quantum with Unity Pro Discrete and Analog I O Reference Manual e Grounding and Electromagnetic Compatibility of PLC Systems User Manual e Modicon Remote I O Cable System Planning and Installation Guide e Modicon Quantum Hot Standby with Unity User Manual e Premium Atrium and Quantum using Unity Pro Communication services and architectures Reference manual e Quantum TCPIP IP Configuration User Manual e Modicon Quantum with Unity Ethernet Network Modules User Manual Test and verify the complete configuration and wiring as part of the commissioning O Use certified Safety and non interfering modules only Functional Safety O Certification page 16 Use modules with the certified firmware versions only Itis possible Functional to check the firmware version of the CPU CRP CRA and NOE Safety O modules as well as that of the CPU Ethernet and CPU Hot Standby Certification processors with the OSloader The firmware o

Modicon Quantum Safety PLC Reference Manual - Barr

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