ABB AC500-S Installation and operating instructions

AC500-S
Usage of AC500 Digital Standard I/Os
in Functional Safety Applications
up to PL c (ISO 13849-1)
Application Note

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Contents
1Introduction _____________________________________________________3
1.1 Purpose .............................................................................................................................3
1.2 Document history...............................................................................................................4
1.3 Validity...............................................................................................................................4
1.4 Important user information..................................................................................................4
1.5 Definitions, expressions, abbreviations...............................................................................4
1.6 References / Related documents........................................................................................5
2Usage of digital standard I/Os in functional safety applications up to PL c _____6
2.1 Overview............................................................................................................................6
2.2 Task...................................................................................................................................8
2.3 Solution..............................................................................................................................8
3Example ______________________________________________________14
3.1 General............................................................................................................................14
3.2 Safety function.................................................................................................................14
3.3 Functional description.......................................................................................................15
3.4 Design features................................................................................................................16
3.4.1 Implementation details 16
3.4.2 Common cause failures 18
3.4.3 Systematic failures 19
3.4.4 Safety function response time 20
3.5 Calculation of the probability of failure and correspondence to PL (ISO 13849-1)..............20
4Conclusion_____________________________________________________23

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1 Introduction
1.1 Purpose
The number of used digital safety input channels in safety applications is often signifi-
cantly higher than the number of digital safetyoutput channels. In some customer PLC
applications, there are often free spare digital standard I/O channels. There is a ques-
tion if thesefree spare digital standard I/O channels can be used together with SM560-
S Safety CPU to realize functional safety functions. If yes, one could avoid using addi-
tional Safety I/O modules with digital safety input channels and, thus, save control sys-
tem costs and reduce control cabinet dimensions in some customer applications.
We analyzed a possible usage of AC500 digital standard I/Os to realize functional
safety functions. This application note describes a possible usage of digital standard
I/O modules from AC500 platform (www.abb.com/PLC) in functional safety application
up to PL c (ISO 13849-1). The functional safety calculation according to ISO 13849-1
is used as an example to show the compliance of the proposed approach with the
relevant functional safety requirements for PL c (ISO 13849-1). The functional safety
calculation according to IEC 62061 standard (applications up to SIL CL 1) can be sim-
ilarly done, if required.
In special cases, digital standard I/O modules from AC500 platform can be also used
in functional safety applications up to PL d (ISO 13849-1) and SIL CL 2 (IEC 62061).
However, more detailed functional safety application analysis is required (contact
AC500 technical support at www.abb.com/PLC for more details) and, thus, is not
shown in this document.

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1.2 Document history
Rev.
Description of
version / c
hanges
Who
Date
1.0.0 Final release ABB 15.12.2015
1.3 Validity
The data and illustrations found in this documentation are not binding. ABB reserves
the right to modify its products in line with its policy of continuous product development.
ABB assumes no liability or responsibility for any consequences arising from the use
of this document information. ABB is in particular in no way liable for missed profits,
loss of income, loss of life, loss of use, loss of production, capital costs or costs asso-
ciated with an interruption to operation, the loss of expected savings or for indirect or
follow up damages or losses no matter of what kind.
1.4 Important user information
This documentation is intended for qualified personnel familiar with Functional Safety.
You must read and understand the safety concepts and requirements presented in
AC500-S Safety User Manual [1] as well as further referenced documents prior to op-
erating AC500-S Safety PLC system.
The following special notices may appear throughout this documentation to warn of
potential hazards or to call attention to specific information.
DANGER
The notices referring to your personal safety are highlighted in the
manual by this safety alert symbol, which indicates that death or
severe personal injury may result if proper precautions are not
taken.
NOTICE
This symbol of importance identifies information that is critical for
successful application and understanding of the product. Itindicates
that an unintended result can occur if the corresponding information
is not taken into account.
1.5 Definitions, expressions, abbreviations
AC500 ABB PLC, refer also to www.abb.com/PLC for further details

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AC500-S ABB Safety PLC for applications up to SIL3 (IEC 61508 ed. 2 and
IEC 62061) and PL e (ISO 13849-1), refer also to
www.abb.com/PLC for further details
AB Automation Builder (ABB Automation Builder is the integrated soft-
ware suite for machine builders and system integrators which co-
vers the engineering of ABB AC500 PLC, AC500-S Safety PLC,
control panels, drives, motion and robots)
CCF Common Cause Failure
CPU Central Processing Unit
DCavg Diagnostic Coverage - average
DPRAM Dual-ported Random Access Memory
IEC International Electro-technical Commission Standard
I/O Input/Output
EMC Electromagnetic compatibility
FB Function Block
FSDT Functional Safety Design Tool (ABB tool for functional safety calcu-
lation according to ISO 13849-1 and/or IEC 62061)
MTBF Mean Time Between Failures
MTTFd Mean Time To Failure dangerous
PFH Probability of Failure per Hour (1/h)
PL Performance Level according to ISO 13849-1
PLC Programmable Logic Controller
SIL Safety Integrity Level (IEC 61508 ed. 2)
TÜV Technischer Überwachungs-Verein (Technical Inspection Associa-
tion)
1.6 References / Related documents
[1] AC500-S Safety User Manual, 3ADR025091M0204
[2] Cyclic Non-safe Data Exchange between SM560-S Safety CPU and PM5xx
Non-Safety CPU, 3ADR025195M0201
[3] BGIA Report 2/2008e, Functional safety of machine controls - Application of
EN ISO 13849
[4] AC500 Documentation, refer to www.abb.com/PLC and then navigate to
Downloads area

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2 Usage of digital standard I/Os in functional safety
applications up to PL c
2.1 Overview
In this document, we discuss the usage of AC500 digital standard I/O modules on the
input side of AC500-S Safety PLC. The output side has to be implemented using safety
output modules as further explained in the notice below. SM560-S Safety CPU has to
be used for safety logic processing and diagnostic measures for digital standard I/O
modules.
NOTICE
Usage of standard output channels on standard I/O modules in
AC500 platform for functional safety applications is not considered
in this document because of the complexity of its implementation in
practice and results in very limited cost saving (two output channels
from two different standard output modules will be needed (contact
ABB technical support at www.abb.com/PLC for more details)). As
a result, safety output channels from DX581-S module [1] or built-
in drive safety functions (Safe Torque Off, Safe Stop 1, Safely Lim-
ited Speed, etc.) accessible through PROFINET / PROFIsafe [1]
shall be used on the output side of the Safety PLC.
Figure 1 gives an overview on the minimumexemplary AC500 configuration to be used
for PL c safety functions with digital standard I/O modules (PM573 standard CPU and
DC523 digital standard I/O modules are taken as examples here but other CPUs and
I/O modules from the AC500 range could also be used).
DX581-S digital safetyinput/output module is includedin Figure 1 as one of options for
Safety PLC output part (another option is the usage of PROFINET/PROFIsafe com-
munication to trigger safety functions in drives with safety option). In addition to avail-
able digital safety input channels on DX581-S, one can use digital standard I/O chan-
nels from standard I/O modules, like DC523.

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Figure 1. Basic setup with AC500/AC500-S modules for usage of AC500 digital
standard I/O modules in functional safety application up to PL c
Remote digital standard I/O modules can be used as well (refer to www.abb.com/PLC
for more details on available AC500 modules).

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2.2 Task
We want to show and describe an approach how AC500 digital standard I/O channels
can be used for functional safety applications up to PL c (ISO 13849-1) in combination
with SM560-S Safety CPU.
NOTICE
It is always highly recommended to use digital safety input channels
even for functional safety applications up to PL c (ISO 13849-1).
Thus, the presented approach with the usageof digital standard I/O
channels is only an option if spare digital standard I/O channels are
available and their reuse for functional safety functions up to PL c
is needed to satisfy specific customer requirements (e.g., limited
space in the control cabinet to add additional digital safetyI/O mod-
ule, cost saving, etc.).
Customer benefits from using spare AC500 digital standard I/O channels for functional
safety applications up to PL c (ISO 13849-1) are:
- Smaller control cabinet dimensions are possible
- Cost savings on additional Safety I/O modules.
2.3 Solution
The proposed solutionis based on the design analysis andadditional diagnostic safety
measures which can be implemented using AC500/AC500-S setup shown in Figure 1
to enable usage of AC500 digital standard I/O channels in functional safety applica-
tions up to PL c (ISO 13849-1).
Figure 2 shows an overview on reachable Performance Levels depending on Cate-
gory, DCavg and MTTFd values, as defined in ISO 13849-1. As one can see from
Figure 2 (see a selection in blue), one of the most attractive approaches to satisfy PL
c (MTTFd = High or Medium) and even PL d (MTTFd = High) requirements is the usage
of Category 2, DCavg = Low.

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Figure 2. Relationship between Categories, DCavg, MTTFd of each channel and PL
from ISO 13849-1 with a focus on Category 2
Category 2 architecture based on ISO 13849-1 is shown in Figure 3.
Figure 3. Category 2 architecture from ISO 13849-1

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Key requirements for Category 2 (ISO 13849-1) are:
- Requirements of systemB (refer to ISO 13849-1 for details) and the use of well-
tried safety principles shall apply
- Safety function shall be checked at suitable intervals by the machine control
system
- The occurrence of a fault can lead to the lossof the safety function between the
checks
- The loss of safety function is detected by the check
Category 2 architecture realization using AC500/AC500-S modules (see Figure 1) is
shown in Figure 4.
Figure 4. Category 2 equivalent architecture using AC500/AC500-S modules
As one can see from Figure 4, safety logic processing and safety output part are fully
covered by SM560-S Safety CPU (SIL3, PL e) and DX581-S digital safety input/output
module, which even significantly exceed the requirements from PL c (ISO 13849-1).
Nevertheless, we need an additional analysis for the input partin which standard (non-
safety) AC500 modules (DC523 and PM573) are used. This input part will be always
application-specific and will require additional measures to satisfy PL c requirements.

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DANGER
In special cases (e.g., if two sensors are connected to two AC500
digital I/O channels from different I/O modules in parallel, etc.), dig-
ital standard I/O modules from AC500 platform can be also used in
functional safety applications up to PL d (ISO 13849-1) and SIL CL
2 (IEC62061). However,more detailed functional safetyapplication
analysis is required (contact AC500 technical support at
www.abb.com/PLCfor more details), which isnot shown in this doc-
ument.
To fulfill PL c (ISO 13849-1) requirements for input part, special DC measures shall be
implemented according to ISO 13849-1. The following measure was selected for the
input part:
- Cyclic test stimulus by dynamic change of the input signals, which provides DC
= 90% (see Annex E, ISO 13849-1)
The exemplary realization of this measure in AC500/AC500-S setup is presented in
Figure 5 and is based on some assumptions, which are later described in Chapter 3 in
details:
- Generation of dynamic pulses is done e.g., from non-safety PM5xx program but
the supervision of the test pulse pattern is done on SM560-S Safety CPU
oFor data exchange between SM560-S and PM5xx two options can be
used:
§SF_DPRAM_PM5XX_S_REC and
SF_DPRAM_PM5XX_S_SEND FBs from Safe-
tyExt_AC500_V22.lib [1] or
§Cyclic Non-safe Data Exchange [2]
DANGER
50 Hz and 60 Hz frequencies shall be avoided for dynamic pulse
generation to avoid electrical noise interference.
- The safety reaction is triggered by SM560-S Safety CPU (in our example
through DX581-S digital safetyinput/output module), if the expected test pattern
is not available.
oStuck-at-1 error are covered by the test pulse test
oCross-talk between other channels can be implemented using time-
shifted (unique) dynamic test pulses for different input channels or differ-
ent test pulse frequencies
DANGER
Additional fault exclusion argumentation is required to exclude the
availability of similar periodic signals (with the same frequency as
that selected for dynamic test pulse generation on DC523 (see Fig-
ure 5)) within PM573 CPU.

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Figure 5. Exemplary realization of cyclic test stimulus by dynamic change of the input
signals using AC500 digital standard I/O module
In Figure 5, Channel C16 of DC523 is configured as an output and Channel C0 is
configured as an input. Test pulses (for example, with LOW phase duration of 10 ms,
HIGH phase duration of 50 ms and a period of 60 ms) are generated on Channel C16
using PM573 application program and are read back through Channel C0 to which
normally-closed position switch S1 is connected. Using DPRAM data exchange (two
options are available, refer to [1] and [2], respectively), one can transfer the observed
signal pattern to SM560-S Safety CPU for supervision. If the test pulse pattern (both
LOW and HIGH phases are supervised) is not available, the safety reactionis triggered
to stop the machine, e.g., through DX581-S digital safety input/output module.

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Figure 6 shows how dynamic signal is transferred from position switch S1 (there could
be also two position switches, as it is shown in Figure 6, e.g., if PL d (ISO 13849-1)
safety applications have to be realized) to SM560-S Safety CPU and then, if safety
request exists, further through DX581-S to the actuator, which was not shown in Figure
5 for simplicity (refer to [1] on details for connections of actuators to DX581-S outputs).
Figure 6. Sequence diagram for dynamic signal supervision using SM560-S Safety
CPU
The proposed approach with AC500 digital standard I/O modules in functional safety
applications up to PL c (ISO 13849-1) is analysed with more details in an example in
Chapter 3.

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3 Example
The following example describes the safety analysis and implementation needed for
AC500 digital standard I/O module usage in functional safety applications up to PL c
(ISO 13849-1). In our example, we refer to the AC500/AC500-S setup described in
Figure 5.
3.1 General
We will provide only a safety analysis with the supporting calculation for the Safety
PLC part in the safety loop, which means that values for sensor and actuator parts will
be omitted for simplicity. We aim to reach ~ 15 % of safety loop PFH equivalent for PL
c (ISO 13849-1), as it is shown in Figure 7 [1].
Figure 7. A typical safety loop with Safety PLC [1]
The safe stopping of the woodworking machine with PL c (ISO 13849-1) is discussed
in our example. The presented safety analysis for Safety PLC part can be similarly
applied for other safety functions up to PL c (ISO 13849-1).
3.2 Safety function
The safety function in this example is the actuation of the “Off” switch (see S1 in Figure
5), which leads to SS1 (Safe Stop 1) with a controlled stop of the motor within a maxi-
mum permissible time.

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3.3 Functional description
- The motor stop is initiated by the actuation of “Off” switch S1 (Normally-closed
contact) which is connected to DC523 digital standard input channel. DC523
digital standard input channel is read by the Safety CPU SM560-S. The digital
safety output channel of the DX581-S safety I/O module is connected to SS1
terminal of the drive with safety option (this part is omitted in Figure 5 for sim-
plicity). DX581-S safety output channels are controlled from SM560-S Safety
CPU and can be deactivatedif the safety reaction is requested through S1.The
drive with built-in safety option is responsible for safe braking.
- SM560-S Safety CPU, DX581-S digital safety I/O module and safety option of
the drive are all certified for SIL CL 3 (IEC 62061) and PL e (ISO 13849-1). In
this example, we will further analyse only Safety PLC (Input, Logic Processing
and Output) parts. The safety analysis of “Off” switch S1 and drive with safety
option is omitted for simplicity.
- A special measure “Cyclic test stimulus by dynamic change of the input signal”
for fault detection is implemented for digital standard input channel on DC523
module, as it is shown in Figure 5. This test signal is able to detect “Stuck-At-1”
errors on the path from digital standard input channel on DC523 module until
the signal is available on the Safety CPU SM560-S. Short-circuit on the input
channel of DC523 module against the ground is a safe error which leads to a
safe state. If needed in the given application (if more than one input channels
on DC523 module are used), cross-talk failures against other dynamic signals
for other input channels on DC523 or other input modules can be implemented
in the application program on SM560-S as well. For example, phase-shifted
pulses or pulses with different frequencies shall be used for selected channels
in the latter case and an additional supervision on SM560-S application program
shall be implemented (it is always application-specific).
- Fault exclusion for dynamic signal with the same frequency as one used on the
digital standard input channel of DC523 shall be performed for AC500 imple-
mentation part (all data transfer paths from DC523 till SM560-S Safety CPU).
DANGER
Fault exclusion for dynamic signal with the same frequency shall be
performed not only as part of wire cross-talk detection but also as a
part of standard (non-safe) signal state transferfrom DC523 module
to the SM560-S Safety CPU through internal I/O bus, PM573 CPU
and then internal coupler bus communication to SM560-S Safety
CPU.

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3.4 Design features
3.4.1 Implementation details
The following steps shall be considered during the implementation of the proposed
approach (see Figure 5) for usage of digital standard I/Os in functional safety applica-
tions up to PL c (ISO 13849-1) in our example:
1. Use channel C16 of DC523 as an output in PM573 standard CPU programand
implement continuous pulsing (periodic TRUE and FALSE phases), as it is
specifiedin Figure5,using e.g.,TONFB. Onecanalso define adedicated cyclic
task on PM573 with 5 ms cycle and priority = 10 to continuously change the
value of channel C16 in the software loop keeping the periodic pulse behaviour
as it is shown in Figure 5.
NOTICE
The selected cycle time for test pulse generation task on standard
CPU program will influence the generated test pulse pattern.
The supervision of the test pattern (length of LOW and HIGH
phases) will be implemented on the Safety CPU. Thus, any devia-
tion of the test pulse pattern will be detected by the Safety CPU,
which will have to trigger the safe state for the given input channel
in case of a wrong test pattern.
2. Continuously read C0 input channel (with input delay parameter (refer to [4] for
details) set to 1 ms for input channels) of DC523 module in the application pro-
gram on PM573 CPU (make sure that the cycle time on the PM573 task is
properly selected, e.g., 2 ms cycle time with cyclic behaviour and priority = 11
for the task are proper ones for the given example).
3. Activate continuous sending of C0 channel value from PM573 application pro-
gram to SM560-S Safety CPU application program for safe test pattern super-
vision. To send C0 channel value to SM560-S from PM573, one can use:
a. SF_DPRAM_PM5XX_S_REC and SF_DPRAM_PM5XX_S_SEND FBs
from SafetyExt_AC500_V22.lib [1] or
b. Cyclic Non-safe Data Exchange [2], which has higher performance of
data transfer than using SF_DPRAM_PM5XX_S_REC and
SF_DPRAM_PM5XX_S_SEND FBs.

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DANGER
You have to keep in mind that data transfer from PM573 to SM560-
S (both using FBs SF_DPRAM_PM5XX_S_REC and
SF_DPRAM_PM5XX_S_SEND and Cyclic Non-safe Data Ex-
change) and backwards is a non-safe function. The usage of this
communication is suitable for PL c (ISO 13849-1) only as applica-
tion specificimplementation with theusageof describedtestpulsing
and test pattern supervision on SM560-S Safety CPU.
The implementation, verification and validation of the approach in
practice according to ISO 13849-1 and/or IEC 62061 will remain al-
ways application specific because standard (non-safety) AC500
modules become involved in the execution of functional safety func-
tions. Thus, the responsibility for correct implementation, verifica-
tion and validation of the proposed approach is fully within the end-
customer responsibility.
NOTICE
Make sure that proper “Min Update Time” setting is selected for
SM560-S Safety CPU in Automation Builder. 2 or 3 ms are recom-
mended for the proposed example.
NOTICE
Make sure that proper cycle time value is used in SM560-S Safety
CPU application program, e.g., the maximum cycle time of 3 ms for
SM560-S Safety CPU is acceptable for the given application exam-
ple.
4. Continuously read C0 channel value on SM560-S safety application program
(the implementation depends on which method was selected in Step 3) and su-
pervise the pattern availability using safety application logic, for example, using
safety TON FBs [1]. Another option is to use two SF_Antivalent FB instances
[1]:a. For LOW (0 V) phase supervision: Selected SF_Antivalent inputs are,
for example, S_ChannelNC := FALSE, S_ChannelNO:= IS_DC523_S1,
DiscrepancyTime := T#35ms;
b. For HIGH (+24 V) phase supervision: Selected SF_Antivalent inputs
are, for example, S_ChannelNC := IS_DC523_S1, S_ChannelNO:=
TRUE, DiscrepancyTime := T#400ms
Where IS_DC523_S1 is the variable name of the transferred C0 channel value
on SM560-S Safety CPU application program. “Error” outputs of SF_Antivalent
FB shall be used as a result of safety pattern supervision on DC523 input chan-
nel C0 and shall be further used in SF_EmergencyStop and SF_SafetyRequest
FBs (see [1] for more details) to properly implement emergency stop function-
ality.

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NOTICE
The data transfer (C0 channel state) from DC523 to PM573 and
then further to SM560-S Safety CPU introduces some time jitter.
The largest introduced time jitter is usually caused by
SF_DPRAM_PM5XX_S_REC and SF_DPRAM_PM5XX_S_SEND
FBs. This leads to longer supervised time values (e.g., LOW phase
of 35 ms and HIGH phase of 400 ms can be used as limits) than
those specified in Figure 5. These limit values can, however, vary
depending on selected settings fortasks onPM573, SM560-S, “Min
Update Time” parameter for SM560-S and selected data transfer
method between PM573 and SM560-S.
NOTICE
Due to the introduced jitter in the used test signal pattern, as one
could see from Step 4, the effective input delay used for C0 input
channel becomes 35 ms (DiscrepancyTime := T#35ms, see Step 4
above). The longest tolerated HIGH phase (+24 V) before “Stuck-
At-1” error is detected and then safe reaction is triggered (to be im-
plemented as part of the safety application program) becomes (Dis-
crepancyTime := T#400ms, see Step 4 above). These values shall
be further used in SFRT and fault reaction time calculations.
NOTICE
The test rate (the test period of 450 ms was used in the given ex-
ample) for input part of the safetyfunction shall be atleast 100 times
greater than the demand rate upon the safety function, as required
for Category 2 (ISO 13849-1).
This requirement is fulfilled in the given example for PL c safety
function if the demand is less than 1 per 45 seconds.
3.4.2 Common cause failures
All measures for CCF are already covered for AC500-S Safety PLC modules like
SM560-S and DX581-S, which are certified for up to PL e (ISO 13849-1) and SIL CL 3
(IEC 62061) safety applications. However, for all AC500 standard (non-safety) mod-
ules, like PM573 and DC523, the estimation of CCF effect shall be performed using
Annex F, ISO 13849-1.
We use below the scoring process and quantification of measures against CCF based
on Annex F, ISO 13849-1:
1. Physical separation between signal paths, refer to AC500 design process
(see Chapter 3.4.3) – 15 points
- Sufficient clearances and creepage distanceson printed-circuit boards
2. Design/application/experience (Protection against overvoltage), refer to
AC500 design process (see Chapter 3.4.3) – 15 points
3. Environmental (EMC, etc.), refer to CE declaration type test report for a
given AC500 product – 25 points

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4. Environmental (Other influences - shock, vibration and temperature), refer
to CE declaration type test report for a given AC500 product – 10 points
Total sum of points: 65 points
As a result, according toISO 13849-1, CCFrequirements for usageof AC500 products
are fulfilled because 65 points are needed for this based on Annex F, ISO 13849-1.
DANGER
A physical separation of signal lines for AC500standard input chan-
nels have to be considered on the application level as well. Thus,
the responsibility for this part remains fully within the end-customer
responsibility.
3.4.3 Systematic failures
Measures for the control and avoidance of systematic failures from Annex G, ISO
13849-1 shall be considered for standard (non-safety) AC500 components separately
(all thesemeasures are already covered for AC500-S Safety PLCmodules like SM560-
S and DX581-S, which are certified for up to PL e (ISO 13849-1) and SIL CL 3 (IEC
62061) safety applications). The AC500 product requirements for the control and
avoidance of systematic failure in PL c (ISO 13849-1) applications are satisfactorily
coveredin the proposed implementation (refer to the systemsetup in Figure 5) through
ABB AC500 product development model:
- Usage of Integrated Management System which is ISO 9001 certified by exter-
nal certification body
- Quality guidelines for software development
- Hardware development process including hardware quality statistics for at least
last 3 years
- Continuous analysis of all critical bug entries in the bug tracking system
All used AC500 modules have CE declaration (European Conformity) available which
means that they satisfy Low Voltage Directive 2006/95/EG, EMC Directive
2004/108/EG and IEC 61131-2:2007 standard requirements in addition to various
other standards (refer to www.abb.com/PLC for details).
DANGER
If standard (non-safety) modules are used for safety functions, one
still have to perform a systematic failure analysis (refer to Annex G,
ISO 13849-1) on the application level for the application part in
which standard (non-safety) modules are used.

Application Note for “Usage of AC500 digital standard I/Os in functional safety applications up to PL c (ISO 13849-1)”, V1.0.0
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3.4.4 Safety function response time
SFRT calculation shall be done based on the data presented in Chapter 5 [1]. It is
straight-forward for all functional safety modules, like SM560-S and DX581-S, but re-
quire additional analysis for standard (non-safety) ones, like PM573 and DC523.
Under assumptions and implementation aspects listed in Chapter 3.4.1, one can add
the following fault error reaction time (e.g., for Stuck-At-1 errors) for DC523input chan-
nel:- 400 ms, if supervised as proposed in Chapter 3.4.1.
As for SFRT input part (it means SFRT up to SM560-S Safety CPU only), one shall
add the fault error reaction time for DC523 path (400 ms in the given example, refer to
Chapter 3.4.1) to a LOW phase supervision time (35 ms in the given example, refer to
Chapter 3.4.1) as the overall worst-case response time, which will result in SFRT for
input part:
- 435 ms, if supervised as proposed in Chapter 3.4.1
DANGER
You still have to do a complete SFRT calculation for the safety
loop(s) (not only input part but also logic processing and output
parts) in your application (see Chapter 5 [1]).
3.5 Calculation of the probability of failure and correspondence to
PL (ISO 13849-1)
For calculation of the probability of failure for Safety PLC part, we will use ABB FSDT
software (see www.abb.com). Our goal is to confirm that PFHavg is (refer to Figure 7)
below or equal to 15% of PL c for Category 2 (refer also to PFHavg values listed in
Table K1 of ISO 13849-1 for given Category, DC and MTTFd values).