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Safety Manager Universal Safety IO
Safety Manager Universal Safety IO supports 2 module types:
x FC-RUSIO-3224 Universal Safety IO
x FC-RUSLS-3224 Universal Safety Logic Solver
Both module types enable maximum architectural flexibility when safety is
required at local and remote locations. They have the unique feature that each
channel can be configured individually to be AI, DI, DO or AO. Every module has
a capacity of 32 freely configurable channels.
Figure 57 — Safety Manager Universal Safety IO Module
By applying the proven in use Quadruple Modular Redundancy (QMR)
technology, uninterrupted process operation is guaranteed, even during on-
process modifications or upgrades, the safeguarded process continues to operate
at the highest safety level and maximum process availability.
The Universal Safety IO modules support universal 2 wire termination and are
certified to be used in TUV SIL1, SIL2 and SIL3 applications. The robust design
makes them suitable for harsh conditions and extreme temperature ranges
allowing a broad field of application.
Safety Manager Universal Safety IO modules are available in redundant and
non-redundant configurations allowing adaption to safety and availability
requirements.
Interfacing into Safety Manager is established via the SIL3 certified SM RIO link
infrastructure. A maximum of 28 modules (Redundant and/or Non-Redundant)
may be configured in one network. Both module types can be used within the
same network fully adapting the specific safety requirements. Universal Safety
IO modules are compatible with existing Safety Manager configurations which
easily can be extended with Universal Safety IO technology.
Safety Manager Universal Safety IO modules do support the TÜV certified On
Line Modification methodology. Application configuration changes, channel
configuration changes, network topology modifications and addition or removal
of Safety Manager Universal Safety IO modules can be done on line without
disturbing the process.
Safety Manager Universal Safety IO supports HART pass through. HART enabled
field devices connect directly to the module field terminals. Without the need of
any additional infrastructure the detailed HART diagnostic information will be
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available within Honeywell’s Field Device Manager (FDM) enabling cost effective
maintenance and maximized process uptime.
Local time stamping is supported via Low Latency SOE. It enables time stamping
with high accuracy. All SOE within the safety solution is gathered via Safety
Manager and made available via Experion SOE event log.
All relevant process and system diagnostics details related to Safety Manager
Universal Safety IO modules are available within Safety Manager and will be
visualized via Safety Builder and Experion.
Safety Manager Universal Safety IO modules may also be used and configured in
a Safety Manager Advanced Redundancy Technique (A.R.T) architecture.
FC-RUSIO-3224, Universal Safety IO
Being an integrated part of the Safety Manager architecture,
all Universal Safety IO (FC-RUSIO-3224, Figure 58) configured channels
will be interfaced to Safety Manager. This means a transparent
safety application allowing tag’s allocated to the Safety Manager Universal
Safety IO to be used on Functional Logic Diagrams (FLD). These
tags will be executed within Safety Managers’ Quad
Processor Pack (QPP) execution environment.
Figure 58 — FC-RUSIO-3224 Universal Safety IO
Safety Manager Universal Safety IO works independent yet integrated from
Safety Manager, this means that failure’s on Universal Safety
IO modules or the RIO link network will not influence the
availability of Safety Manager. As Safety Manager Universal Safety IO executes
it’s own diagnostic algorithms, it will go to a predefined safety state even when
the communication to Safety manager is lost.
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FC-RUSLS-3224, Universal Safety Logic Solver
The Universal Safety Logic Solver module ((FC-RUSLS-3224, Figure 59) provides
it’s own execution environment and has the capacity to execute Functional Logic
Diagrams (FLD’s) locally.
Figure 59 — FC-RUSLS-3224 Universal Safety Logic Solver
As the execution environment of the Safety Manager Universal Safety Logic
Solver works independent from Safety Manager it allows the
Safety Manager Universal Safety Logic Solver to remain operational even when
the communication to Safety Manager is disturbed or when
Safety Manager is in shutdown. The locally safeguarded process
continues to operate at the highest safety level and maximum
process availability. Because the Universal Safety Logic Solver works
independent from the Safety Manager it is suitable for applications which require
a low cycle time. The cycle time of the Universal Safety Logic Solver depends on
the IO configuration and complexity of the logics.
Safety Manager Universal Safety Logic Solver supports all
functions and features of Universal Safety IO (FC-RUSIO-3224)
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Communication with Safety Manager Universal Safety IO
Safety Manager Universal Safety IO integrate to Safety Manager via SM RIO
Link, a SIL3 propriety protocol specifically designed for Universal Safety IO type
modules to achieve maximum safety & reliability for local and remote locations.
It supports localized and distributed safety solutions or a mix of these.
Up to 28 redundant Universal Safety IO modules may be connected to a Safety
Manager. This allows for approximately 900 freely configurable IO channels as
an addition to conventional Safety Manager Chassis IO channels.
A maximum of six certified switch levels can be used between Safety Manager
and any Universal Safety IO module, the maximum distance is 100 km.
The universality of the channels, the capability to be installed on remote
locations and the robust design allowing it to be used in harsh conditions makes
these modules ideal for wellhead, offshore and pipeline applications.
Safety Manager Universal Safety IO can be used for safety solutions which are
localized, distributed or a mix of both.
Figure 60 shows a typical layout of a safety solution using both Chassis IO and
Safety Manager Universal Safety IO for a local and remote locations.
Figure 60 — Example of a Safety Manager Universal Safety IO
communication layout
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Safety Manager Universal Safety IO components
The Safety Manager Universal Safety IO solution consists out of different
components:
x Mounting Carrier,
x IO termination Assembly,
x Universal Safety IO modules
x Redundant Power supply Assembly
Assembled together it forms a 32 channel Universal Safety IO solution
(see Figure 61)
MCAR
IOTA
Figure 61 — Safety Manager Universal Safety IO assembly
Mounting Carrier
The standard Mounting Carrier (MCAR) is a carrier that can be screwed on any
flat surface. It is suitable to carry one assembly.
The MCAR consists of:
x a metal profile
x a plastic cover plate
x a ground rail with 16 ground connection screws
x two power rails with M5 holes (+24V and 0V)
x stacking option for multiple MCARs (per 3 ft)
x four mounting holes (6.35 mm diameter)
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Redundant IO Termination Assembly
The Redundant IO Termination Assembly (IOTA) allows the use of a redundant
set of Safety Manager Universal Safety IO modules. (See also Figure 61)
An IOTA provides for:
• Connectors for two (redundant) Universal Safety IO modules.
• 32 (universal) IO channel connections (CN1 and CN2).
• Two power switches to switch off the Universal Safety IO modules.
• Enable / Disable SM RIO ESD function for CH32.
• 4 (identical) V+ connections (CN3), for active AI devices.
• Two RJ45 connectors for RIO Link A and RIO Link B.
• Node Address jumper
• 24V power connection screws to the carrier power rails.
Non-Redundant IO Termination Assembly
The Non-Redundant IO Termination Assembly (IOTA) allows the use of a Safety
Manager Universal Safety IO module.
An IOTA provides for:
• Connectors for a single Universal Safety IO module.
• 32 (universal) IO channel connections (CN1 and CN2).
• a power switch to switch off the Universal Safety IO modules.
• Enable / Disable SM RIO ESD function for CH32.
• 4 (identical) V+ connections (CN3), for active AI devices.
• Two RJ45 connectors for RIO Link A and RIO Link B.
• Node Address jumper
• 24V power connection screws to the carrier power rails.
Safety Manager Universal Safety IO
The Safety Manager Universal Safety IO module is a series-C form factor IO
module for Safety applications.
It interfaces via a Safety Manager and is suitable for SIL1, SIL2 and SIL3 safety
applications. The device functions as a Universal Safety IO module within the
Safety Manager architecture. It executes:
x the input scan of the process variables,
x all functional tests of its hardware,
x data exchange with its partner module,
x update the outputs and thus the process,
x data exchange via the SM RIO link with the SM Controller that executes the
application logics (FC-RUSIO-3224 Universal Safety IO),
x data exchange via the SM RIO link with the SM Controller that acts as the
gateway (FC-RUSLS-3224 Universal Safety Logic Solver),
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Safety Manager Universal Safety IO modules do provide for:
x 32 Universal Safety IO channels with configurable channel function
x All channels are powered out of the 24Vdc supply.
x Supports two (redundant) SIL3 SM RIO Links to communicate with a SM
Controller.
Each channel can be configured as:
x Digital input (DI) (with or without loop monitoring)
x Digital output (DO) (with or without loop monitoring)
x Analog input (AI) (0-20mA or 4-20mA active)
x Analog output (AO) (0-20mA or 4-20mA active)
x Smoke/Heat detector
As a standard solution Safety Manager Universal Safety IO is suitable to be used
in:
Class 1 Div 2 environments
ATEX Zone 2 environments
Redundant Power Supply Assembly
For standard Safety Manager Universal Safety IO solutions, a Redundant Power
Supply assembly is available. (See Figure 62)
The power supply assembly provides:
- Redundant 25Vdc, 12 A power,
- Embedded Power distribution,
- Certified for SIL1, SIL2 and SIL3 safety applications,
- Wide temperature range (-40 to +70C,-40 to +158F)
One Power supply carrier has:
- two AC power input connectors for redundant feeders.
- one 25 Vdc power output connector to connect the MCAR.
- four fused 25Vdc output connectors to connect auxiliary equipment.
- one fault output connector.
- two power supply units
x Power in: 102-132 Vac, 196-253 Vac, 47-63Hz
x Power out: 25Vdc, 12A
Figure 62 — Universal Safety IO Redundant Power Supply
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Safety Manager Universal Safety IO special features
Line Monitoring
As a default all available IO configurations are equipped with line monitoring
functionality. This allows for both lead breakage and short circuit detection for all
channels configured without the need for special and/or dedicated hardware.
High current outputs
For some applications High Load Outputs may be required, for these
applications the Safety Manager Universal Safety IO output channels can be
combined to drive higher currents to the field. Safety Manager Universal Safety
IO allows to combine up to 4 output channels enabling a 2 A output.
Configuration is simply done via application software and physically via a 4 pins
fork (see Figure 63). This allows for a easy and flexible configurations of 500mA
(standard), 1A and 2A output channels.
Figure 63 — Universal Safety IO High current output configuration
ESD input
Safety Manager Universal Safety IO is equipped with a special configurable ESD
(Emergency Shut Down) input allowing to switch off al the configured Digital
Outputs in case of an unwanted situation in the process unit controlled by this
Safety Manager Universal Safety IO module. This concept allows for controlled
emergency shutdowns only to those areas affected.
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Safety Manager Universal Safety IO Field Terminal Assemblies
Safety Manager Universal Safety IO supports universal 2 wire termination and
allows for a direct connection of field devices to the terminals located on the
IOTA.
To support application specific requirements, a suite of Field Terminal
Assemblies (FTA) are available for Safety Manager Universal Safety IO solutions.
These FTA’s will enable the support of 3 wire field devices, high power output
requirements (Fire and Gas) and high voltage IO support.
x FC-TSKUNI-1624 SM RIO Safe FTA Knife, 24Vdc,16ch
x FC-TSPKUNI-1624 SM RIO Safe FTA Knife, 3-wire,24Vdc,16ch
x FC-TDOL-0724U SM RIO DO FTA, loop mon, 2A, 24VDc, 7ch
x FC-TSRO-0824 DO(relay) FTA for SIL3 appl. 8ch CC
x FC-TSRO-08UNI DO(relay) FTA SIL3 common power 8ch CC
These FTA’s do require special System Interconnection Cables (SIC), please refer to
the Safety Manager Part list (SM.PL.6803) to get more detail
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Standard Safety Manager Universal Safety IO Solutions
Within the Safety Manager Product portfolio, standard Field Device Units are
defined. These standard solutions contain certified components and are
developed to be used under certain environmental conditions.
The Standard Universal Safety IO solutions may be equipped with both types:
x FC-RUSIO-3224 Universal Safety IO
x FC-RUSLS-3224 Universal Safety Logic Solver
Depending on the requirements, the architecture can be redundant, non-
redundant or a mix of these.
Standard Field Device Unit for normal operational conditions
The Standard Field Device Unit for normal operational conditions (Figure 64) is a
small field device unit which is a fully self supporting remote IO unit with 32 IO
channels, embedded redundant field power and redundant SM RIO Link fiber
optic connections, it contains:
- Safety Manager Universal Safety IO system with 32 freely configurable IO
Channels
- Steel cabinet,
- Communication via Fiber 100Km ,
- Earth Leakage Detection,
- Temperature range -5°C to +60°C (+23°F to +140°F)
Standard Field Device Unit for extreme operational
conditions
The Standard Field Device Unit for extreme operational conditions is a small field
device unit which is a fully self supporting remote IO unit with 32 IO channels,
embedded redundant field power and redundant SM RIO Link fiber optic
connections, it contains:
- Safety Manager Universal Safety IO system with 32 freely configurable IO
Channels
- Stainless Steel (ANSI 316L) cabinet,
- Communication via Fiber 100Km ,
- Temperature range -40°C to +70°C (-40°F to +158°F)
Figure 64 — Standard Field Device Unit
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Standard Rittal TS8 SM RIO Cabinet
The SM RIO full size Rittal TS8 (Figure 65) cabinet is based on the Rittal TS8808
cabinet. Typical used when more than 96 channels of Safety Manager Universal
Safety IO is needed on remote locations. It contains:
- Safety Manager Universal Safety IO modules only
- Default 800x800x2000mm, Steel,
- Front and rear access
- Maximum 14 redundant SM RIO modules (448 channels).
- Communication via Fiber 100Km
- Standard power supplies
- Earth Leakage Detection
- Temperature range -5°C to +60°C (-23°F to +140°F)
Figure 65 — TS8 SM RIO Cabinet
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Safety Manager Universal Safety IO Zone 1 Solution.
For Safety Manager Universal Safety IO Zone 1 requirements a standard EEx d
box is defined
The EEx d box as shown in Figure 66, contains a redundant Universal Safety IO
module,
Redundant SM RIO link communication infrastructure and a redundant Power
supply assembly.
The Safety Manager Universal Safety IO Zone 1 solution supports 32 Universal
Safety IO channels and it includes certification.
Depending on the requirements the Safety Manager Universal Safety IO Zone 1
box may be equipped with:
x FC-RUSIO-3224 Universal Safety IO
x FC-RUSLS-3224 Universal Safety Logic Solver
Additional to this, the required isolators on interface boards and/or field
termination assemblies are located within the box.
Three solution variations are available, depending on application requirements
and connected devices:
x Type 01/04 for all field devices with no Ex d housing => Exi signals
x Type 02/05 for a combination (50/50) of field devices with and without Ex d
housing.=> Ex d signals and Exi signals
x Type 03/06 for all field devices with Ex d housing => Ex d signals
Figure 66 — Safety Manager Universal Safety IO Zone 1 EEx d box
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For the Exi signals Pepperl+Fuchs isolators and the integration board FC-GPCS-
RIO16-PF are used. On this integration board any combination of the following
type of P+F isolators can be placed:
x Digital input SIL2: HIC2831R2,
x Digital Input SIL3: HIC2853R2,
x Analog input SIL2: HIC2025,
x Digital output 24Vdc SIL3: HIC2871, or
x Analog output SIL2: HIC2031
The Safety Manager Universal Safety IO Zone 1 box has the following
certifications:
x ATEX II 2GD Exd [ia] IIBT6 or ATEX II 2GD Exd IIBT6 IP66
x Certificate INERIS 10ATEX0035X
x Ambient temperature -20C /+60C
Two types of materials are available for the boxes:
Enclosure type SS:
x Material finish: Stainless Steel 316 L
x Ingress protection (acc. EN 60529): IP66
x Dimensions (WxHxD): 920x670x300mm
x Gross weight (without IO modules): 221 kg
x 2x Eyebolt M14 on top of enclosure
x 1x VDR14 1/4" SS drain valve( in short bottom side)
x 1x Welded coupling with threaded hole 1/8’’ISO for VDR14
x 24x Welded coupling with threaded hole M32x1,5 in bottom side
x 13x Welded coupling with threaded hole M32x1,5 in right hand low side
Enclosure type AL:
x Material finish: Aluminum Alloy
x Ingress protection (acc. EN 60529): IP66
x Dimensions (WxHxD): 915x670x310mm
x Gross weight (without IO modules): 132 kg
x 2x Eyebolt M14 on top of enclosure
x 1x VDR14 1/4" SS drain valve( in short bottom side)
x 1x Welded coupling with threaded hole 1/8’’ISO for VDR14
x 24x Welded coupling with threaded hole M32x1,5 in bottom side
x 13x Welded coupling with threaded hole M32x1,5 in right hand low side
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Safety Manager Field Device Unit (SM-FDU)
The Safety Manager Field Device Unit (FDU) is a combination of Safety Manager
and Safety Manager Universal Safety IO into a compact unit (see Figure 67
below) that meets safety standards for Safety Level SIL1, SIL2 or SIL3 out of
the box, reducing start-up and lifecycle costs for smaller applications.
Figure 67 — Safety Manager Field Device Unit (SM-FDU)
The Safety Manager FDU system is designed to allow process manufacturers to
more easily implement small, standalone safety applications in their facilities.
The offering integrates Honeywell’s widely used Safety Manager Safety
instrumented System (SIS) platform and the Universal Safety IO modules into a
single, space-friendly unit that arrives SIL3 certified out of the box.
The FDU module’s small size makes it ideal for plants that need to quickly
implement integrated safety measures for applications such as burner or boiler
management systems. This is critical due to increasingly stringent safety
regulations and compliance standards, which often times force manufacturers to
upgrade or even replace existing safety equipment. For example, an outdated,
non-compliant panel in a boiler management system could be replaced with the
FDU in the limited space close to the boiler. The Safety Manager FDU’s flexibility
enables plants to implement better fitting solutions into their existing
environments, even if they don’t require complete safety offerings.
