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Allen-Bradley GuardLogix 5580 User Manual

Allen-Bradley GuardLogix 5580
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GuardLogix 5580 and Compact GuardLogix 5380
ControllerSystems
Catalog Numbers 1756-L81ES, 1756-L82ES, 1756-L83ES, 1756-L84ES, 1756-L8SP, 1756-L81ESK, 1756-L82ESK,
1756-L83ESK, 1756-L84ESK, 1756-L8SPK, 5069-L306ERMS2, 5069-L306ERS2, 5069-L310ERMS2, 5069-L310ERS2,
5069-L320ERMS2, 5069-L320ERS2, 5069-L320ERS2K, 5069-L320ERMS2K, 5069-L330ERMS2, 5069-L330ERS2,
5069-L330ERS2K, 5069-L330ERMS2K, 5069-L340ERMS2, 5069-L340ERS2, 5069-L350ERMS2, 5069-L350ERS2,
5069-L350ERS2K, 5069-L350ERMS2K, 5069-L380ERMS2, 5069-L380ERS2, 5069-L3100ERMS2, 5069-L3100ERS2
Safety Reference Manual
Original Instructions

Table of Contents

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Allen-Bradley GuardLogix 5580 Specifications

General IconGeneral
SeriesGuardLogix 5580
I/O CapacityUp to 256 I/O modules
Programming EnvironmentStudio 5000 Logix Designer
Safety Integrity LevelSIL 3
Performance LevelPL e
Controller TypeSafety Programmable Logic Controller (PLC)
ProcessorDual-core
I/O SupportDigital, Analog, Safety I/O
Communication ProtocolsEtherNet/IP, ControlNet, DeviceNet
Operating Temperature0°C to 60°C (32°F to 140°F)
CertificationsUL, CE

Summary

Chapter 1 Safety Integrity Level (SIL) Concept

SIL Certification

Provides SIL certifications and Performance Level for controllers.

Proof Tests

Discusses requirements for performing proof tests of equipment used in safety systems.

GuardLogix Architecture

Provides examples of SIL 3 and SIL 2 systems and how devices connect.

Controller Specifications

Lists product specifications and agency certifications for controllers.

System Reaction Time

Defines system reaction time as the worst-case time from event to safe state.

Safety Task Period and Safety Task Watchdog

Explains the safety task period and the maximum permissible time for processing.

Contact Information If Device Failure Occurs

Provides contact details for reporting device failures to Rockwell Automation.

Chapter 2 GuardLogix Controller System

GuardLogix 5580 Controller Hardware

Describes the GuardLogix 5580 controller, its primary controller, and safety partner.

Compact GuardLogix 5380 Controller Hardware

Details the SIL 2 capable Compact GuardLogix 5380 controller and its components.

Network Communication

Provides examples of network communication configurations, including EtherNet/IP.

DeviceNet Safety Network

Explains how DeviceNet bridges enable communication with Safety I/O modules.

Programming Overview

Guides on using Studio 5000 Logix Designer for programming GuardLogix safety controllers.

Chapter 3 Safety I/O for the GuardLogix Control System

Typical Safety Functions of Safety I/O Devices

Explains how Safety I/O devices are treated as safe states.

Reaction Time

Defines input and output reaction times and their calculation.

Safety Considerations for Safety I/O Devices

Covers commissioning, ownership, and configuration of Safety I/O devices.

Safety I/O Configuration Signature

Explains the safety I/O configuration signature and its verification.

Safety I/O Device Replacement

Details procedures for replacing safety I/O devices and their configuration.

Chapter 4 CIP Safety and Safety Network Numbers

Unique Node Reference

Explains the concept of a Unique Node Reference (UNID) in CIP Safety protocol.

Safety Network Numbers (SNN)

Describes how Safety Network Numbers (SNN) are assigned to subnets.

Routable CIP Safety System

Illustrates the extent of a routable CIP Safety system.

Considerations for Assigning SNNs

Provides guidelines on automatically generating and manually assigning SNN values.

How SNNs Get to Safety Devices

Explains how Safety Network Numbers are assigned to safety devices.

SNN Formats

Details the two formats for SNNs: Time-based and Manual.

SNNs for Out-of-box Devices

Explains how SNNs are set for out-of-box CIP Safety I/O devices.

Chapter 5 Characteristics of Safety Tags, the Safety Task, and Safety Programs

Differentiate Between Standard and Safety

Explains the distinction between standard and safety components in GuardLogix systems.

The Safety Task

Details the characteristics and limitations of the safety task in GuardLogix controllers.

SIL 2 and SIL 3 Safety Application Differences

Compares requirements for SIL 2 and SIL 3 safety applications.

Safety I/O Modules

Discusses differences in I/O modules for safety integrity levels.

Use of Human Machine Interfaces

Provides precautions and guidelines for using HMIs in SIL-rated GuardLogix systems.

Access to Safety-related Systems

Covers reading and changing parameters in safety-related systems via HMIs.

Safety Programs

Defines safety programs and their attributes, including scheduling and scope.

Safety Routines

Describes safety routines, their limitations, and usage within safety programs.

Safety Tags

Explains safety tags, their attributes, and composition.

Standard Tags in Safety Routines (Tag Mapping)

Details mapping standard tags into safety tags for synchronization.

Chapter 6 Safety Application Development

Safety Concept Assumptions

Outlines requirements for creating, operating, and maintaining safety applications.

Basics of Application Development and Testing

Recommends practices for developing and testing safety applications.

Commissioning Lifecycle

Illustrates the steps required for commissioning a GuardLogix safety system.

Specification of the Safety Function

Guides on creating a safety function specification for verification.

Create the Project

Details requirements for creating application logic and instructions.

Test the Application Program

Describes the process of testing the application program.

Generate the Safety Signature

Explains how to generate a safety signature for controller operation.

Validate the Project

Guides on checking the application program against the specification.

Confirm the Project

Outlines steps to confirm the downloaded, tested, and retained safety program.

Safety Assessment

Discusses the requirement for independent third-party review of safety systems.

Lock the Controller

Recommends safety-locking the controller to protect safety components.

Download the Safety Application Program

Details requirements for downloading the safety application program.

Upload the Safety Application Program

Explains how to upload the safety signature and tag values from the controller.

Store and Load a Project from a Memory Card

Covers firmware updates and program storage using a memory card.

Force Data

Explains how to force data for safety-unlocked projects without signatures.

Inhibit a Device

Details how to inhibit specific safety I/O devices or producer controllers.

Online Editing

Covers guidelines for performing online edits on safety logic.

Editing Your Safety Application

Outlines rules for changing safety application programs in Studio 5000.

Performing Online Edits

Details the process and impact of performing online edits on safety programs.

Modification Impact Test

Explains the need to plan and analyze modifications for impact on safety systems.

Chapter 7 Monitor Status and Handle Faults

Status Indicators

Explains the use of status indicators for general diagnostics.

Monitoring System Status

Guides on viewing safety tag connection status and device operating status.

I/O Device Connection Status

Describes how CIP Safety protocol allows data recipients to determine data status.

De-energize to Trip System

Explains the de-energize to trip system where zero is the safe state.

Get System Value (GSV) and Set System Value (SSV) Instructions

Details using GSV/SSV instructions to get/set controller system data.

Safety Faults

Categorizes faults in GuardLogix and Compact GuardLogix systems.

View Faults

Explains how to view faults using the Controller Properties dialog box.

Fault Codes

Shows fault codes specific to GuardLogix and Compact GuardLogix controllers.

Safety Partner Fault

Describes the OK status indicator and faults related to the safety partner.

Appendix A Safety Instructions

Safety Instructions

Lists safety application instructions certified for SIL 2 or SIL 3 applications.

Appendix B Create and Use a Safety Add-On Instruction

Create an Add-On Instruction Test Project

Guides on creating a unique test project for creating and testing Add-On Instructions.

Create a Safety Add-On Instruction

Provides guidance on creating Add-On Instructions using Logix5000 Controllers manual.

Generate the Instruction Signature

Explains the instruction signature for determining if an instruction has been modified.

The Safety Instruction Signature

Defines the safety instruction signature as an ID identifying execution characteristics.

SIL 2 or SIL 3 Add-On Instruction Qualification Test

Details performing tests for SIL 2 or SIL 3 Add-On Instructions.

Safety Validate Add-On Instructions

Discusses third-party review requirements for safety Add-On Instructions.

Create Signature History Entry

Explains how to create a signature history entry for future reference.

Export and Import the Safety Add-On Instruction

Provides guidelines for exporting and importing safety Add-On Instructions.

Verify Safety Add-On Instruction Signatures

Explains comparing signatures to ensure the validity of imported Add-On Instructions.

Test the Application Program

Describes the process of getting an application to run properly.

Project Validation

Guides on performing engineering tests of the application and safety system.

Safety Assessment

Discusses third-party review requirements for safety system approval.

Appendix C Reaction Times

Connection Reaction Time Limit

Defines the maximum age of safety packets on a connection before a fault occurs.

Specify the Requested Packet Interval (RPI)

Explains how RPI specifies the period for data updates over a connection.

View the Maximum Observed Network Delay

Describes how to view and reset the Maximum Observed Network Delay.

System Reaction Time

Defines system reaction time and its components.

Logix System Reaction Time

Explains how to calculate Logix system reaction time for various chains.

Simple Input-logic-output Chain

Describes Logix system reaction time for a simple input to logic to output chain.

Logic Chain Using Produced/Consumed Safety Tags

Explains Logix system reaction time for chains using produced/consumed safety tags.

Factors That Affect Logix Reaction-time Components

Identifies factors influencing Logix Reaction Time components.

Configure Guard I/O Input Module Delay Time Settings

Guides on configuring input module delay time in Studio 5000 Logix Designer.

Configure or View the Input and Output Safety Connection Reaction Time Limits

Details how to configure input/output safety connection reaction time limits.

Configure the Safety Task Period and Watchdog

Explains how to select safety task period, priority, and watchdog time.

Access Produced/Consumed Tag Data

Provides steps to view or configure safety-tag connection data.

Appendix D Checklists for GuardLogix Safety Applications

Checklist for GuardLogix Controller System

A checklist for planning, programming, and starting a GuardLogix safety application.

Checklist for Safety Inputs

An individual checklist for every safety input in the system.

Checklist for Safety Outputs

An individual checklist for every safety output in the system.

Checklist to Develop a Safety Application Program

A checklist to help maintain safety when creating or modifying a safety application.

Appendix E GuardLogix Systems Safety Data

Useful Life

States the useful life of GuardLogix controllers is 20 years.

Safety Data

Provides safety data, including PFD and PFH values for safety I/O modules.

Product Failure Rates

Presents safety parameters and calculations related to product failure rates.

Appendix F Studio 5000 Logix Designer Application, Version 31 or Later, Safety-application Instructions

De-energize to Trip System

Explains how safety input values are set to safe state upon CIP Safety connection fault.

Use Connection Status Data to Initiate a Fault Programmatically

Provides examples of application logic to latch and reset I/O failures.

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