INOR IPAQ C520 Wiring diagram

HART
®
Temperature Transmitter
for up to SIL 2 applications
Safety manual SIL
Safety manual SILSafety manual SIL
Safety manual SIL
IPAQ C520/R520
IPAQ C520/R520IPAQ C520/R520
IPAQ C520/R520 Supplementary Instructions
Supplementary InstructionsSupplementary Instructions
Supplementary Instructions
© INOR 02/2019 - 86B520S001 - AD 520 SIL R1.4 en

CONTENTS
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IPAQ C520/R520
1 Introduction 3
1.1 Field of application ........................................................................................................... 3
1.2 User benefits .................................................................................................................... 3
1.3 Manufacturer’s safety instructions.................................................................................. 3
1.4 Relevant standards / Literature....................................................................................... 4
2 Terms and definitions 5
3 Description of the subsystem 6
3.1 Functional principle.......................................................................................................... 6
4 Safety function 8
4.1 Description of the failure categories ............................................................................... 8
4.2 Specification of the safety function .................................................................................. 8
4.3 Redundancy ...................................................................................................................... 9
4.3.1 Sensor drift ........................................................................................................................... 10
4.3.2 Sensor backup ...................................................................................................................... 10
5 Project planning 11
5.1 Applicable device documentation .................................................................................. 11
5.2 Project planning, behaviour during operation and malfunction.................................... 11
5.2.1 SIL data ................................................................................................................................. 11
6 Periodic checks / Proof tests 12
6.1 Periodic checks .............................................................................................................. 12
6.2 Proof tests ...................................................................................................................... 12
7 Safety-related characteristics 14
7.1 Assumptions ................................................................................................................... 14
7.2 Specific safety-related characteristics .......................................................................... 15
8 Appendix 20
8.1 Declaration of conformity for Functional Safety (SIL) ................................................... 20
8.2 exida / FMEDA management summary ......................................................................... 21
8.3 Type Examination Certificate ......................................................................................... 24
8.4 Return / maintenance form............................................................................................ 26
9 Notes 27

INTRODUCTION 1
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1.1 Field of application
The IPAQ C520 (hereafter referred to as C520) is a universal, isolated, dual-input temperature
transmitter for RTD and thermocouple sensors. It’s primarily intended to be mounted in a DIN-B
housing.
IPAQ R520 (hereafter referred to as R520) is the rail mounted version of the IPAQ C520.
IPAQ C520X and R520X are the intrinsically safe versions of the IPAQ C520 and R520.
An S is added for the SIL versions, e.g. C520S and C520XS.
The IPAQ C520/R520 temperature transmitter utilizes a modular design in hardware as well as
in software to ensure the quality and reliability of the transmitter signal output to meet the
special safety requirements according to IEC 61508:2010 part 1 to part 3 for use in SIL2
applications.
1.2 User benefits
•This intelligent HART
®
temperature transmitter is designed to perform temperature
measurements of solids, fluids and gases up to SIL2 according to special safety requirements
of IEC 61508:2010 (see Certificate No. SC0266-13 issued by RISE Research Institute of
Sweden AB (former SP Technical Research Institute of Sweden).
•Remote configuration with process control system, PC or HART
®
hand terminal is not
notnot
not
possible in combination with SIL activation to prevent unintended changes, only read-out of
parameters from the unit is possible via HART
®
. To change settings or deactivate the SIL
function the INOR software ConSoft and INOR USB-kit ICON must be used.
•Continuous measurement
•Easy commissioning
SIL 2 requirements are based on the standard IEC 61508:2010.
The C520S/C520XS/R520S/R520XS certification involves the HW assessment of the products with
an FMEDA plus a full assessment made by RISE Research Institute of Sweden AB.
1.3 Manufacturer’s safety instructions
The measuring device has been built and tested in accordance with the current state of the art,
and complies with the relevant safety standards
However, dangers may arise from improper use or use for other than intended purpose.
For this reason, observe all the safety instructions in this document and in the Handbook
carefully.
Hardware Production
order no.
IPM OPM ConSoft Handbook Safety Manual
≤9 ≤571029873 01.01.03xxx 01.01.04xxx ≥2.0.0.8 86B5200001 ≤2 86B520S001 ≤R1.2
≥11 ≥571030029 01.02.02xxx 01.02.02xxx
01.02.03xxx
≥2.0.0.8 86B5200001 ≥4 86B520S001 ≥R1.3

1 INTRODUCTION
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1.4 Relevant standards / Literature
This "Safety manual" is a complement to the regular Handbook(User Instructions) for IPAQ C520
and R520.
In addition to the safety rules in this documentation, national and regional safety rules and
industrial safety regulations must also be observed.
Standard Designation
IEC 61508:2010
all parts Functional safety of electrical/electronic/programmable electronic safety related systems – Part 2: Requirements for electrical/electronic/programmable electronic safety-related
systems
IEC 61326-3-1:2008
EN 61326-3-1:2008 Immunity requirements for safety-related systems and for equipment intended to perform safety-related functions (functional safety)- General industrial applications
Namur NE 21 Electromagnetic compatibility of industrial process and laboratory control equipment
Namur NE 32 Data retention in the event of a power failure in field and control instruments with
microprocessors
Namur NE 43 Standardization of the signal level for the failure information of digital transmitters
Namur NE 53 Software of field devices and signal processing devices with digital electronics
Namur NE 79 Microprocessor equipped devices for safety instrumented systems
Namur NE 89 Temperature transmitter with digital signal processing
Namur NE 107 Self-monitoring and diagnosis of field devices
EN 60079-0:2009
EN 60079-0:2012 Electrical apparatus for explosive gas atmospheres - Part 0: General requirements
EN 60079-11:2007
EN 60079-11:2012 Explosive atmospheres - Equipment protection by intrinsic safety "i"
EN 60079-26:2007
EN 60079-26:2015 Explosive atmospheres - Part 26: Equipment with equipment protection level (EPL) Ga
Table 1-1: Supported standards during the development of C520/R520

TERMS AND DEFINITIONS 2
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Used abbreviations
Acronym Description
DC
D
Diagnostic Coverage of dangerous failures.
Diagnostic coverage is the ratio of the detected failure rate to the total failure rate.
FIT Failure In Time (1x10
-9
failures per hour)
FMEA Failure Modes Effects Analysis is a structured qualitative analysis of a system,
subsystem, process, design or function to identify potential failure modes, their
causes and their effects on (system) operation.
FMEDA Failure Modes Effects and Diagnostic Analysis adds a qualitative failure data for all
components being analyzed and ability of the system to detect internal failures via
automatic on-line diagnostics parts to FMEA.
HFT Hardware Fault Tolerance
Low demand mode Mode, where the frequency of demand for operation made on a safety-related
system is not greater than one per year and not greater than twice the proof-test
frequency.
High demand
mode Mode, where the frequency of demands for operation made on a safety-related system is greater than one per year and greater than twice the proof-check
frequency.
MTBF Mean Time Between Failure is average time between failure occurrences.
MTTR Mean Time To Restoration is average time needed to restore normal operation after
a failure has occurred.
PFD
AVG
Probability of Failure on Demand is the average probability of a system to fail to
perform its design function on demand.
PFH Probability of Failure per Hour is the probability of a system to have a dangerous
failure occur per hour.
SFF Safe Failure Fraction summarizes the fraction of failure, which lead to a safe state
and the fraction of failures which will be detected by diagnostic measures and lead
to a defined safety action.
SIF Safety Instrumented Function
SIL Safety Integrity Level
Type A component
/ Type A element "Non-complex" subsystem (all failure modes are well defined); for details see 7.4.3.1.2 of IEC 61508-2:2000 / 7.4.4.1.2 of IEC 61508-2:2010.
Type B component
/ Type B element "Complex" subsystem (at least one failure mode are not well defined); for details see 7.4.3.1.3 of IEC 61508:2000 / 7.4.4.1.3 of IEC 61508-2:2010.
T[Proof] Proof Test Interval
Table 2-1: Used abbreviations during the development of C520/R520

3 DESCRIPTION OF THE SUBSYSTEM
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3.1 Functional principle
The C520/R520 supports up to two sensor channels with general input circuits that may be
configured for RTD and/or thermocouple temperature sensors.
All safety related calculations are based on these connections.
Functional principle of the C520/R520 is based on the analog to digital and back to analog signal
conditioning. The temperature sensors used are either Resistance Temperature Device(s) (RTD)
or thermocouple(s) (T/C). The RTD has a temperature dependent, non-linear, variable resistance
while the T/C generates a low level, highly non-linear, EMF (voltage) that depends on the
temperature difference between opposite ends of the T/C wire pair. Hence the connection end of
the T/C (cold junction) constitutes a temperature reference or base value that has to be
measured in order to determine the temperature at the critical spot (hot junction). This action is
referred to as cold junction compensation (CJC). One or two sensors of the same or different
types may be connected.
The low level analogue signal from temperature sensors is amplified and filtered before
converting it to a digital signal. The digital signal is less prone to electromagnetic interference.
Digital signal processing like sensor linearization, calculation, temperature drift compensation
etc. is controlled by processors, isolated and converted back to analogue 4...20 mA output signal.
Figure 3-1: The functional principle of C520
1 Primary Master
2 HART modem
3 HART
4 Milliampere-meter Load ≥250Ω
5 Terminal 7 (- on C520)
6 4...20 mA
7 Terminal 6 (+ on C520)
8 C520 connected with sensor in the sensor head
9 Secondary master
10 DC power supply
11 Load ≥250Ω

DESCRIPTION OF THE SUBSYSTEM 3
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The C520/R520 are smart temperature transmitter which improves predicting problems within
the industrial safety instrumented systems –SIS, reducing the manual testing.
The C520/R520 is a modular and configurable system with the ability to pre-configure inputs for
measuring sensor(s) and outputs to fault conditions. Configuration of the transmitter is
protected by password.

4 SAFETY FUNCTION
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4.1 Description of the failure categories
The following definitions of the failure are used during diagnostic calculations:
4.2 Specification of the safety function
The safety function of the C520/R520 transmitter is the quality and reliability of the transmitter
signal output, i.e. measurement performance, error detection and error indication in the signal-
processing path of the transmitter.
The valid range of the output signal is between 3.8 mA and 20.5 acc. to NE 43.
The failure information is defined by two selectable alarm levels: Fail Low (Downscale ≤3.6 mA)
and Fail High (Upscale ≥21 mA).
The configuration of the transmitter is protected by a password set via the software ConSoft. The
password is stored in the transmitter.
The C520S/C520XS/R520S/R520XS checks sensor errors (sensor break or sensor short) for both
channels if it is configured in this manner.
State definition Description
Fail-Safe State The fail-safe state is defined as the output reaching the user defined
threshold value.
Fail - Safe A safe failure (S) is defined as a failure that causes the
module/(sub)system to go to the defined fail-safe state without a demand
from the process. Safe failures are divided into safe detected (SD) and safe
undetected (SU) failures.
Fail Dangerous A dangerous failure is defined as a failure of the temperature transmitter
C520/R520 not responding to a demand from the process, i.e. being unable
to go to the defined fail-safe state, and the output current deviates by
more than 2% of measuring span of the actual temperature measurement
value.
Fail Dangerous Undetected Failure that is dangerous and that is not being diagnosed by internal
diagnostics.
Fail Dangerous Detected Failure that is dangerous but is detected by internal diagnostics and
causes the output signal to go to the predefined alarm state (These
failures may be converted to the selected fail-safe state).
Fail High Failure that causes the output signal to go to the maximum output current
(≥21 mA) acc. to NAMUR NE 43.
Fail Low Failure that causes the output signal to go to the minimum output current
(≤3.6 mA) acc. to NAMUR NE 43.
Fail No Effect Failure of a component that is part of the safety function but is neither a
safe failure nor a dangerous failure and has no effect on the safety
function. For the calculation of the SFF it is treated like a safe undetected
failure.
Not part Failures of a component which is not part of the safety function but part of
the circuit diagram.
Table 4-1: Definitions of the failure rate during the diagnostic calculations for C520/R520.

SAFETY FUNCTION 4
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A software SIL-switch is available in the transmitter, handled by the PC-configuration software
ConSoft. It is password-protected by the same password that protects from change of
configuration. The SIL-switch can also be changed by HART communication, still password-
protected. The password may be changed either via ConSoft or via HART communications. It is
stored in the transmitter and it has to be accurate in order to download any changes to the
transmitter configuration. When the transmitter is shipped, the password default value is “0000”.
For SIL applications the password must be changed
For SIL applications the password must be changedFor SIL applications the password must be changed
For SIL applications the password must be changed to a user specific password in order to
prevent unintended change of configuration.
The following definitions of the failure are used during diagnostic calculations:
1For some system failures the alarm output will toggle between a high alarm level (≥21.0 mA)
and a low alarm level (≤3.6 mA). For some HW failures the alarm level will be high even though a
low level is configured and for some other HW failures the alarm will go low even though a high
level has been selected.
To prevent a safety system from restart due to the toggling output the system should be setup so
that once an alarm signal has occurred from the safety loop the system shouldn’t go back to
normal run automatically but only manual ("Restart Interlock").
2Transmitter errors = failures in the software or hardware detected by the diagnostics in the
transmitter.
3The sensor drift function is valid from SW-versions; IPM-SW 01.01.03 and OPM-SW 01.01.04
and hardware versions 5 and later, implemented in transmitters with serial number 1006.xxxxxx
or later. Serial number 1006.xxxxxx means manufactured week 6 in 2010 and this information is
found on the nameplate or it can be read from the transmitter via ConSoft. The software and
hardware versions can be read from the ConSoft software, tab "Device Information".
4.3 Redundancy
For the following configurations:
•2 x 2w RTD sensors
•2 x 3w RTD sensors
•2 x 4W RTD sensors (only valid for R520S/R520XS)
•2 x Thermocouple sensors
•1x Thermocouple sensor and 1 x 3w RTD sensor
•1x Thermocouple sensor and 1 x 4w RTD sensor (only valid for R520S/R520XS)
are either "Sensor drift monitoring" function or "Sensor backup" function selectable at a time.
Function Active/Not Active Output Alarm level 1
Sensor break Active 4...20 mA / 20...4 mA ≤3.6 mA / ≥21.0 mA
Sensor short Active 4...20 mA / 20...4 mA ≤3.6 mA / ≥21.0 mA
Low isolation Not active - -
Transmitter error 2Active 4...20 mA / 20...4 mA ≥21.0 mA
Sensor drift (dual
sensor needed) 3Active/Not Active selectable 4...20 mA / 20...4 mA ≤3.6 mA / ≥21.0 mA

4 SAFETY FUNCTION
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4.3.1 Sensor drift
If the function "Sensor drift" monitoring is selected, a difference between the sensors of more or
equal to the value stated in the configuration will cause the output to go either "Downscale" or
"Upscale" depending on the user configuration. Maximum temperature difference has to be
specified in °C via ConSoft.
4.3.2 Sensor backup
If "Sensor backup" function is activated the sensor chosen as output measuring in the
configuration will reflect the actual measuring value as long as it’s working properly. A sensor
break or a sensor short cause the transmitter to switch over to the other sensor and the output
signal will reflect the measured value of that sensor. A diagnostic message is transmitted via
HART
®
to the PLC.
If the "Average" function is activated in the configuration, the output value will reflect the actual
mean measuring value as long as the sensors are working properly. A sensor break or a sensor
short cause the transmitter to switch over to the non-broken sensor and the output signal will
reflect the measured value of that sensor. A diagnostic message is transmitted via HART
®
to the
PLC.
The functions "Sensor backup" and "Average" doesn't give any extra safety according to SIL and
are not used for calculating the system (transmitter + sensor) safety figures.
CAUTION!
The possibility to select the function for sensor drift monitoring is implemented in software
revision IPM-SW 01.01.03 and OPM-SW 01.01.04, from serial number 1006.xxxxxx.