Adjustable speed electrical power drive systems - Part 5-2: Safety requirements - Functional

IEC 61800-5-2:2016 is available as IEC 61800-5-2:2016 RLV which contains the International Standard and its Redline version, showing all changes of the technical content compared to the previous edition.
IEC 61800-5-2:2016 specifies requirements and makes recommendations for the design and development, integration and validation of safety related power drive systems (PDS(SR)) in terms of their functional safety considerations. It applies to adjustable speed electrical power drive systems covered by the other parts of the IEC 61800 series of standards as referred in IEC 61800-2. IEC 61800-5-2, which is a product standard, sets out safety-related considerations of PDS(SR)s in terms of the framework of IEC 61508, and introduces requirements for PDS(SR)s as subsystems of a safety-related system. It is intended to facilitate the realisation of the electrical/ electronic/programmable electronic (E/E/PE) parts of a PDS(SR) in relation to the safety performance of safety sub-function(s) of a PDS. This edition includes the following significant technical changes with respect to the previous edition:
a) rational added in the scope why low demand mode is not covered by this standard,
b) definition added for: "category" and "safety function",
c) "Other sub-functions" sorted into "Monitoring sub-functions" and "Output functions",
d) deleted "proof test" throughout the document because for PDS(SR) a proof test is not applicable,
e) replaced the term "safety function" by "safety sub-function" throughout the document,
f) Updated references to IEC 61508 series Ed.2010,
g) Added the principle rules of ISO 13849-1 and reference to tables of ISO 13849-2,
h) 6.1.6 Text replaced by Table 2,
i) 6.1.7 Integrated circuits with on-chip redundancy matched to changed requirement in IEC 61508-2: 2010, Annex E,
j) 6.2.8 Design requirements for thermal immunity of a PDS(SR)
k) 6.2.9 Design requirements for mechanical immunity of a PDS(SR),
l) 6.1.6 SIL for multiple safety sub-functions within one PDS(SR),
m) 6.1.7 Integrated circuits with on-chip redundancy,
n) 6.2.1 Basic and well-tried safety principles,
o) 6.2.2.1.4 Diagnostic test interval when the hardware fault tolerance is greater than zero,
p) 6.2.5.2.7 PDS(SR) parameterization,
q) 9 Test requirements,
r) 9.3 Electromagnetic (EM) immunity testing,
s) 9.4 Thermal immunity testing,
t) 9.5 Mechanical immunity testing,
u) Annex A Sequential task table,
v) Annex D, D.3.16, Motion and position feedback sensors updated,
w) Annex E Electromagnetic immunity (EM) requirement for PDS(SR),
x) Annex F Estimation of PFDavg value for low demand with given PFH value.

Entraînements électriques de puissance à vitesse variable - Partie 5-2: Exigences de sécurité - Fonctionnelle

L'IEC 61800-5-2:2016 spécifie des exigences et donne des recommandations pour la conception et le développement, l'intégration et la validation des entraînements de puissance relatifs à la sécurité (PDS(SR)), en considération de leur sécurité fonctionnelle. Elle s'applique aux entraînements électriques de puissance à vitesse variable couverts par les autres parties de la série de normes IEC 61800 à laquelle il est fait référence dans l'IEC 61800-2. L'IEC 61800-5-2, qui est une norme de produit, expose des considérations relatives à la sécurité des PDS(SR) prises dans le cadre de l'IEC 61508 et présente des exigences pour les PDS(SR) en tant que sous-systèmes d'un système relatif à la sécurité. Elle est destinée à faciliter la réalisation des parties électriques/électroniques/électroniques programmables (E/E/PE) d'un PDS(SR) en liaison avec la performance de sécurité d'une ou des sous-fonctions de sécurité d'un PDS. Cette édition inclut les modifications techniques majeures suivantes par rapport à l'édition précédente:
a) ajout, dans le domaine d'application, de la justification pour laquelle le mode de fonctionnement à faible sollicitation n'est pas couvert par la présente norme,
b) ajout des définitions de "catégorie" et de "fonction de sécurité",
c) "Autres sous-fonctions" réorganisées en "Sous-fonctions de contrôle" et en "Fonctions de sortie",
d) suppression du terme "essai périodique" dans l'ensemble du document dans la mesure où cet essai n'est pas applicable à un PDS(SR),
e) remplacement du terme "fonction de sécurité" par "sous-fonction de sécurité" dans l'ensemble du document,
f) mise à jour des références à la série IEC 61508 Éd. 2010,
g) ajout des règles de principe de l'ISO 13849-1 et d'une référence aux tableaux de l'ISO 13849-2,
h) 6.1.6 texte remplacé par le Tableau 2,
i) 6.1.7 Modification des Circuits intégrés avec redondance sur la puce pour correspondre aux exigences de l'Annexe E de l'IEC 61508-2:2010,
j) 6.2.8 Exigences relatives à la conception pour l'immunité thermique d'un PDS(SR),
k) 6.2.9 Exigences relatives à la conception pour l'immunité mécanique d'un PDS(SR),
l) 6.1.6 SIL pour plusieurs sous-fonctions de sécurité dans un PDS(SR),
m) 6.1.7 Circuits intégrés avec redondance sur la puce,
n) 6.2.1 Principes de sécurité de base et principes de sécurité éprouvés,
o) 6.2.2.1.4 Intervalle entre essais de diagnostic pour une tolérance aux défauts supérieure à zéro du matériel,
p) 6.2.5.2.7 Paramétrage du PDS(SR),
q) 9 Exigences relatives aux essais,
r) 9.3 Essais d'immunité électromagnétique (EM),
s) 9.4 Essais d'immunité thermique,
t) 9.5 Essais d'immunité mécanique,
u) Annexe A Table de tâches séquentielles,
v) Annexe D, D.3.16, mise à jour de Capteurs de signal de retour de mouvement et de position,
w) Annexe E Exigences d'immunité électromagnétique (EM) pour le PDS(SR),
x) Annexe F Estimation de la valeur PFDmoy pour une faible sollicitation avec la valeur de la PFH donnée.

General Information

Status
Published
Publication Date
17-Apr-2016
Current Stage
PPUB - Publication issued
Start Date
18-Apr-2016
Completion Date
18-Apr-2016
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IEC 61800-5-2
Edition 2.0 2016-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Adjustable speed electrical power drive systems –
Part 5-2: Safety requirements – Functional
Entraînements électriques de puissance à vitesse variable –
Partie 5-2: Exigences de sécurité – Fonctionnelle
IEC 61800-5-2:2016-04(en-fr)
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC 61800-5-2
Edition 2.0 2016-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Adjustable speed electrical power drive systems –
Part 5-2: Safety requirements – Functional
Entraînements électriques de puissance à vitesse variable –
Partie 5-2: Exigences de sécurité – Fonctionnelle
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 13.110; 29.200 ISBN 978-2-8322-3302-3

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® Registered trademark of the International Electrotechnical Commission
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---------------------- Page: 3 ----------------------
– 2 – IEC 61800-5-2:2016 © IEC 2016
CONTENTS

FOREWORD ......................................................................................................................... 6

INTRODUCTION ................................................................................................................... 8

1 Scope ............................................................................................................................ 9

2 Normative references................................................................................................... 10

3 Terms and definitions .................................................................................................. 12

4 Designated safety sub-functions .................................................................................. 18

4.1 General ............................................................................................................... 18

4.2 Safety sub-functions ............................................................................................ 19

4.2.1 General ....................................................................................................... 19

4.2.2 Limit values ................................................................................................. 20

4.2.3 Stopping functions ....................................................................................... 20

4.2.4 Monitoring functions ..................................................................................... 21

4.2.5 Output functions – Safe brake control (SBC) ................................................. 23

5 Management of functional safety .................................................................................. 23

5.1 Objective ............................................................................................................ 23

5.2 Requirements for the management of functional safety ........................................ 23

5.3 PDS(SR) development lifecycle ........................................................................... 23

5.4 Planning of PDS(SR) functional safety management ............................................ 24

5.5 Safety requirements specification (SRS) for a PDS(SR) ....................................... 26

5.5.1 General ....................................................................................................... 26

5.5.2 Safety sub-functions requirements specification ............................................ 26

5.5.3 Safety integrity requirements specification .................................................... 27

5.6 PDS(SR) safety system architecture specification ................................................ 28

5.6.1 General ....................................................................................................... 28

5.6.2 Requirements for safety system architecture specification ............................. 28

6 Requirements for design and development of a PDS(SR) ............................................. 29

6.1 General requirements .......................................................................................... 29

6.1.1 Change in operational status ........................................................................ 29

6.1.2 Design standards ......................................................................................... 29

6.1.3 Realisation ................................................................................................... 29

6.1.4 Safety integrity and fault detection ................................................................ 29

6.1.5 Safety and non-safety sub-functions ............................................................. 30

6.1.6 SIL for multiple safety sub-functions within one PDS(SR) .............................. 30

6.1.7 Integrated circuits with on-chip redundancy .................................................. 31

6.1.8 Software requirements ................................................................................. 31

6.1.9 Design documentation .................................................................................. 31

6.2 PDS(SR) design requirements ............................................................................. 31

6.2.1 Basic and well-tried safety principles ............................................................ 31

6.2.2 Requirements for the estimation of the probability of dangerous random

hardware failures per hour (PFH).................................................................. 31

6.2.3 Architectural constraints ............................................................................... 34

6.2.4 Estimation of safe failure fraction (SFF) ........................................................ 35

6.2.5 Requirements for systematic safety integrity of a PDS(SR) and

PDS(SR) subsystems ................................................................................... 36

6.2.6 Design requirements for electromagnetic (EM) immunity of a PDS(SR).......... 39

6.2.7 Design requirements for thermal immunity of a PDS(SR) ............................... 39

---------------------- Page: 4 ----------------------
IEC 61800-5-2:2016 © IEC 2016 – 3 –

6.2.8 Design requirements for mechanical immunity of a PDS(SR) ......................... 39

6.3 Behaviour on detection of fault ............................................................................ 39

6.3.1 Fault detection ............................................................................................. 39

6.3.2 Fault tolerance greater than zero .................................................................. 39

6.3.3 Fault tolerance zero ..................................................................................... 39

6.4 Additional requirements for data communications ................................................. 39

6.5 PDS(SR) integration and testing requirements ..................................................... 40

6.5.1 Hardware integration .................................................................................... 40

6.5.2 Software integration ..................................................................................... 40

6.5.3 Modifications during integration .................................................................... 40

6.5.4 Applicable integration tests .......................................................................... 40

6.5.5 Test documentation ...................................................................................... 40

7 Information for use ...................................................................................................... 41

7.1 General ............................................................................................................... 41

7.2 Information and instructions for safe application of a PDS(SR) ............................. 41

8 Verification and validation ............................................................................................ 42

8.1 General ............................................................................................................... 42

8.2 Verification .......................................................................................................... 43

8.3 Validation ............................................................................................................ 43

8.4 Documentation .................................................................................................... 43

9 Test requirements ........................................................................................................ 43

9.1 Planning of tests ................................................................................................. 43

9.2 Functional testing ................................................................................................ 43

9.3 Electromagnetic (EM) immunity testing ................................................................ 44

9.3.1 General ....................................................................................................... 44

9.3.2 Intended EM environment ............................................................................. 44

9.3.3 Performance criterion (fail safe state – FS) ................................................... 44

9.4 Thermal immunity testing .................................................................................... 44

9.4.1 General ....................................................................................................... 44

9.4.2 Functional thermal test ................................................................................. 45

9.4.3 Component thermal test ............................................................................... 45

9.5 Mechanical immunity testing ................................................................................ 45

9.5.1 General ....................................................................................................... 45

9.5.2 Vibration test ............................................................................................... 45

9.5.3 Shock test .................................................................................................... 45

9.5.4 Performance criterion for mechanical immunity tests (fail safe state –

FS) .............................................................................................................. 45

9.6 Test documentation ............................................................................................. 45

10 Modification ................................................................................................................. 46

10.1 Objective ............................................................................................................ 46

10.2 Requirements ...................................................................................................... 46

10.2.1 General ....................................................................................................... 46

10.2.2 Modification request ..................................................................................... 46

10.2.3 Impact analysis ............................................................................................ 46

10.2.4 Authorization................................................................................................ 46

10.2.5 Documentation ............................................................................................. 46

Annex A (informative) Sequential task table........................................................................ 47

Annex B (informative) Example for estimation of PFH ......................................................... 51

---------------------- Page: 5 ----------------------
– 4 – IEC 61800-5-2:2016 © IEC 2016

B.1 General ............................................................................................................... 51

B.2 Example PDS(SR) structure ................................................................................ 51

B.2.1 General ....................................................................................................... 51

B.2.2 Subsystem A/B ............................................................................................ 52

B.2.3 Subsystem PS/VM ....................................................................................... 52

B.3 Example PDS(SR) PFH value determination ........................................................ 53

B.3.1 Subsystem “A/B” (main subsystem) .............................................................. 53

B.3.2 Subsystem “PS/VM” ..................................................................................... 58

B.3.3 PFH value of the safety sub-function STO of PDS(SR) .................................. 61

B.4 Reduction of DC and SFF depending on test interval ........................................... 62

Annex C (informative) Available failure rate databases ....................................................... 63

C.1 Databases .......................................................................................................... 63

C.2 Helpful standards concerning component failure .................................................. 63

Annex D (informative) Fault lists and fault exclusions ......................................................... 65

D.1 General ............................................................................................................... 65

D.2 Remarks applicable to fault exclusions ................................................................ 65

D.2.1 Validity of exclusions .................................................................................... 65

D.2.2 Tin whisker growth ....................................................................................... 65

D.2.3 Short-circuits on PWB-mounted parts ........................................................... 65

D.3 Fault models ....................................................................................................... 66

D.3.1 Conductors/cables ....................................................................................... 66

D.3.2 Printed wiring boards/assemblies ................................................................. 66

D.3.3 Terminal block ............................................................................................. 66

D.3.4 Multi-pin connector ....................................................................................... 67

D.3.5 Electromechanical devices ........................................................................... 67

D.3.6 Transformers ............................................................................................... 68

D.3.7 Inductances ................................................................................................. 68

D.3.8 Resistors ..................................................................................................... 68

D.3.9 Resistor Networks ........................................................................................ 68

D.3.10 Potentiometers ............................................................................................. 68

D.3.11 Capacitors ................................................................................................... 68

D.3.12 Discrete semiconductors .............................................................................. 68

D.3.13 Signal Isolation components ......................................................................... 69

D.3.14 Non-programmable integrated circuits .......................................................... 69

D.3.15 Programmable and/or complex integrated circuits ......................................... 69

D.3.16 Motion and position feedback sensors .......................................................... 70

Annex E (normative) Electromagnetic (EM) immunity requirement for PDS(SR) ................... 74

E.1 General ............................................................................................................... 74

E.2 Immunity requirements – low frequency disturbances ........................................... 74

E.3 Immunity requirements – high frequency disturbances ......................................... 77

Annex F (informative) Estimation of PFD value for low demand with given PFH
avg

value .................................................................................................................................. 81

F.1 General ............................................................................................................... 81

F.2 Estimation of PFD value for low demand with given PFH value ....................... 81

avg

Bibliography ....................................................................................................................... 82

Figure 1 – Installation and functional parts of a PDS(SR) ..................................................... 10

Figure 2 – Safety function consisting of safety sub-functions ................................................ 19

---------------------- Page: 6 ----------------------
IEC 61800-5-2:2016 © IEC 2016 – 5 –

Figure 3 – PDS(SR) development lifecycle .......................................................................... 24

Figure B.1 – Example PDS(SR) ........................................................................................... 51

Figure B.2 – Subsystems of the PDS(SR) ............................................................................ 52

Figure B.3 – Function blocks of subsystem A/B ................................................................... 53

Figure B.4 – Reliability model (Markov) of subsystem A/B .................................................... 56

Figure B.5 – Function blocks of subsystem PS/VM .............................................................. 58

Figure B.6 – Reliability model (Markov) of subsystem PS/VM ............................................... 60

Table 1 – Alphabetical list of terms and definitions .............................................................. 12

Table 2 – Example for determining the SIL from hardware and software independence ....... 30

Table 3 – Safety integrity levels: target failure measures for a PDS(SR) safety sub-

function .............................................................................................................................. 32

Table 4 – Maximum allowable safety integrity level for a safety sub-function carried

out by a type A safety-related subsystem ............................................................................ 35

Table 5 – Maximum allowable safety integrity level for a safety sub-function carried

out by a type B safety-related subsystem ............................................................................ 35

Table A.1 – Design and development procedure for PDS(SR) .............................................. 47

Table B.1 – Determination of DC factor of subsystem A/B .................................................... 55

Table B.2 – PFH value calculation results for subsystem A/B ............................................... 58

Table B.3 – Determination of DC factor of subsystem A/B .................................................... 59

Table B.4 – PFH value calculation results for subsystem PS/VM .......................................... 61

Table D.1 – Printed wiring boards/assemblies ..................................................................... 66

Table D.2 – Terminal block ................................................................................................. 67

Table D.3 – Multi-pin connector ........................................................................................... 67

Table D.4 – Electromechanical devices (for example relay, contactor relays) ....................... 68

Table D.5 – Signal Isolation components ............................................................................. 69

Table D.6 – Non-programmable integrated circuits .............................................................. 69

Table D.7 – Programmable and/or complex integrated circuits ............................................. 70

Table D.8 – Motion and position feedback sensors .............................................................. 71

Table E.1 – Minimum immunity requirements for voltage deviations, dips and short

interruptions ....................................................................................................................... 75

Table E.2 – PDS(SR) minimum immunity requirements for voltage deviations, dips and

short interruptions on main power ports with a rated voltage above 1 000 V ......................... 76

Table E.3 – Immunity requirements – high frequency disturbances ....................................... 77

Table E.4 – General frequency ranges for mobile transmitters and ISM for radiated

tests ................................................................................................................................... 79

Table E.5 – General frequency ranges for mobile transmitters and ISM for conducted

tests ................................................................................................................................... 80

---------------------- Page: 7 ----------------------
– 6 – IEC 61800-5-2:2016 © IEC 2016
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
ADJUSTABLE SPEED ELECTRICAL
POWER DRIVE SYSTEMS –
Part 5-2: Safety requirements – Functional
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