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SIL Safety Manual
Bently Nevada* Asset Condition Monitoring
3500/32M_SIL and /33_SIL Relay

Document 115M5936
Rev. - (05/16)
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com
3500/32M_SIL and /33_SIL Relay Modules
© 2016 Bently Nevada, Inc.
All rights reserved.
The information contained in this document is subject to change without notice.
* Denotes a trademark of Bently Nevada, Inc., a wholly owned subsidiary of General Electric
Company.
Bently Nevada, Proximitor
The following are trademarks of the legal entities cited:
Printed in USA. Uncontrolled when transmitted electronically.
Contact Information
The following contact information is provided for those times when you cannot contact your
local representative:
1631 Bently Parkway South

Mailing Address Minden, Nevada USA 89423
USA
1.775.782.3611
Telephone
1.800.227.5514
Fax 1.775.215.2873
Internet www.GEmeasurement.com
115M5936 Rev:- (05/16) ii
Additional Information
NOTE
This manual does not contain all the information required to operate and maintain the product. Refer to the
following manuals for other required information.
3500 Monitoring System Installation and Maintenance Manual (part number 129766-01)
3500 Monitoring System Rack Configuration and Utilities Guide (part number 129777-01)
3500 Field Wiring Diagram Package (part number 130432-01)
3500 Monitoring System Computer Hardware and Software Manual (part number 128158-01)
3500/22M TDI Operation and Maintenance Manual (part number 161580-01)
3500/33 16-Channel Relay Module Manual (part number 162291-01)
3500/33 16-Channel Relay Module Data Sheet (part number 162301-01)
3500/32 and 3500/32M 4-Channel Relay Module Manual (part number 129771-01)
3500/32 and 3500/32M 4-Channel Relay Module Data Sheet (part number 141533-01)
3500 System: Functional Safety Data Sheet (part number 162242-01)
Product Disposal Statement

Customers and third parties, who are not member states of the European Union, who are in
control of the product at the end of its life or at the end of its use, are solely responsible for the
proper disposal of the product. No person, firm, corporation, association or agency that is in
control of product shall dispose of it in a manner that is in violation of any applicable federal,
state, local or international law. Bently Nevada, Inc. is not responsible for the disposal of the
product at the end of its life or at the end of its use.
115M5936 Rev:- (05/16) iii
Contents
1. Purpose 1
1.1 Abbreviations 1
1.2 IEC 61508-2 Annex D Requirements References 3
1.3 References 4
2. Hardware 5
2.1 Rack Interface Monitor 6
2.2 System Power Supplies 6
2.3 Monitors 6
2.4 Relay Modules 7
2.4.1 3500/32M_SIL 4-Channel Relay Module 7
2.4.2 3500/33_SIL 16-Channel Relay Module 9
3. Constraints and SIL Requirements 12
3.1 Skills Required to Commission and Maintain SIL Monitors 12
3.2 SIL 1 Requirements 12
3.2.1 Ordering requirements: 12
3.2.2 Hardware Requirements: 12
3.2.3 Software Requirements: 13
3.3 Recommendations 14
4. Functional Specifications 15
4.1 Systematic Capability 15
4.2 Architectural/Random Constraints, Overview 15
4.2.1 Architectural/ Random Constraints, 1oo1 Configuration 15
4.2.2 Architectural/ Random Constraints, 1oo2 Configuration with Redundant Relay
Paths 17
4.2.3 Architectural/Random Constraints, 1oo2 Configuration with Redundant Controller
and Relay Paths 20
5. Failure Modes 23
5.1 Failure modes of the 3500/32M_SIL and 3500/33_SIL Modules 23
5.2 Failure modes that are not detected by internal diagnostics 23
115M5936 Rev:- (05/16) iv
5.3 Failure modes that are detected by internal diagnostics 23

5.3.1 Diagnostic test interval 24
5.3.2 System Outputs 24
5.3.3 LED Fault Conditions 24
5.4 Failure modes of the diagnostics 24
5.5 External diagnostics 24
6. Periodic Proof Test 25
6.1 Choosing a Periodic Proof Test Interval 25
6.2 Periodic Proof test guide 25
115M5936 Rev:- (05/16) v
1. Purpose
The purpose of this safety manual is to document all the information specifically related to the
functional safety aspects of the 3500/32M_SIL and 3500/33_SIL Relay Modules. These modules
are certified for use as a component in a functional safety system. This safety manual is required
in order to enable the integration of the 3500/32M_SIL and 3500/33_SIL into a safety related
system and to be in compliance with the requirement of IEC 61508-2 Annex D. This manual is
focused on those details which specifically apply to the functional safety use case, and must be
used in conjunction with the standard product documentation for these products.
1.1 Abbreviations
l ANSI/ISA – American National Standard Institute / International Society of Automation
l API - American Petroleum Institute
l ARM – armature
l β – common cause failure factor for undetectable dangerous faults
l βD – common cause failure factor for detectable dangerous faults
l CE – Conformité Européenne (European Conformity)
l DC - diagnostic coverage
l FIT - failures in time
l FMEA - failure mode effect and analysis
l FS – functional safety
l HFT - hardware fault tolerance
l IEC – International Electro-technical Commission
l MRT - mean repair time
l MTBF - mean time between failure
l MTTF - mean time to failure
l MTTR - mean time to restoration
l NC - normally closed
l NDE - normally de-energized
l NE - normally energized
l NO - normally open
l PTC - proof test coverage
l PFD - probability of failure on demand
l SC - systematic coverage
l SFF - safe failure fraction
l SIF – safety instrumented function
115M5936 Rev:- (05/16) 1
l SIL – Safety Integrity Level
l TUV – Technischer Überwachungsverein (Technical Inspection)
l λs = safe failure rate
l λsd = safe detected failure rate
l λsu = safe undetected failure rate.
l λd = dangerous failure rate.
l λdd = dangerous detected failure rate.
l λdu = The dangerous undetected failure rate.
l λ- Common = common failures across all channels
l λ- Redundant = channel specific failures, which would take into account β’s when used in
redundant a 1oo2 configuration
115M5936 Rev:- (05/16) 2
1.2 IEC 61508-2 Annex D Requirements References
The table below provides a reference to which section of this document fulfills the 61508-2
Standard.
IEC 61508 requirements (part 2 annex D) Reference
D2.1 a) a functional specification of the functions capable of being Section 2.4.1 for 3500/32M_SIL
performed Section 2.4.2 for 3500/33_SIL
D2.1 b) identification of the hardware and/or software configuration of Section 2.4.1 for 3500/32M_SIL
the compliant item Section 2.4.2 for 3500/33_SIL
D2.1 c) constraints on the use of the compliant item and/or assumptions

Section 3
on which analysis of the behavior or failure rates of the item are based
D2.2 a) the failure modes of the compliant item due to random

hardware failures, that result in a failure of the function and that are not Section 5.2
detected by diagnostics internal to the compliant item
D2.2 b) for every failure mode in a), an estimated failure rate Section 4
D2.2 c) the failure modes of the compliant item due to random hardware
failures, that result in a failure of the function and that are detected by Section 5.3
diagnostics internal to the compliant item
D2.2 d) the failure modes of the diagnostics, internal to the compliant

item due to random hardware failures, that result in a failure of the Section 5.4
diagnostics to detect failures of the function
Failure rate for D.2.2 c) Section 4

D2.2 e) for every failure mode in c), and d), the estimated failure rate
Failure rate for D.2.2 d) Section 4
D2.2 f) for every failure mode in c) that is detected by diagnostics

Section 5.3
internal to the compliant item, the diagnostic test interval
D2.2 g) for every failure mode in c) the outputs of the compliant item
Section 5.3
initiated by the internal diagnostics
D2.2 h) any periodic proof test and/or maintenance requirements Section 6
D2.2 i) for those failure modes, in respect of a specified function, that

are capable of being detected by external diagnostics, sufficient
Section 5.5
information shall be provided to facilitate the development of an
external diagnostics capability
D2.2 j) the hardware fault tolerance Section 4.2
D2.2 k) the classification as type A or type B of that part of the compliant

Section 4
item that provides the function (see 7.4.4.1.2 and 7.4.4.1.3)
D.2.3 a) The systematic capability of the complaint item or that part of

Section 4.1
the element that provides the function
D.2.3 b) Any instructions or constraints relating to the application of the

compliant item, relevant to the function, that should be observed in Section 3.2
order to prevent systematic failures of the compliant item
115M5936 Rev:- (05/16) 3
1.3 References
IEC 61508, Parts 1 - 7:2010: Functional safety of electrical/electronic/programmable electronic
safety-related systems
API Standard 670, 4th edition, Dec. 2000 Machinery Protection Systems
TÜV Certificate number 968/EZ 323.02/12 dated 2012-08-29
TÜV Certificate number 968/EZ 323.03/14 dated 2014-05-15
Schematic diagram 3500/33 & /32M Relay Control Module, Dwg. No: 149987
Schematic diagram 3500/33 16-Channel Relay IO Board, Dwg. No: 149993
Schematic diagram 3500/32 4-Channel Relay IO Board, Dwg. No: 125721
Statement of Compliance, BN26744C-18
System test procedures, No: 158792, Rev. NC, 28 Nov 1995
Copy of ISO 9001 certificate, issued by Det Norske Veritas, 11 Oct. 2001
115M5936 Rev:- (05/16) 4
2. Hardware
The 3500 system is a rack based machinery protection and condition monitoring system that
provides information to protect and assess the mechanical condition of rotating and
reciprocating machinery. The 3500 system continuously measures and monitors various
protection and supervisory parameters and provides important information for early
identification of machinery problems such as imbalance, misalignment, shaft crack, and bearing
failures. The 3500 system is composed of monitors which accept inputs from transducers,
condition the signals to provide various measurements, and compares the conditioned signals
with user-programmable alarms. These alarm statuses are generated and broadcast onto the
system alarming networks. Also in this system are relay modules that observe the alarming
networks, and drive relays based on user programmable relay logic.
In SIL Certified systems, the safety function is supported by one or more SIL certified monitors
which supply alarm and status information to one or more relay modules that consume the
information to resolve machine trip logic and drive their relay output(s). These relay outputs are
the monitoring system’s safety output function. The relay outputs, are intended to be used in the
greater Safety Instrumented Function (SIF) to bring the process to a safe state.
A basic 3500 system consists of a rack chassis, a backplane circuit board, redundant power
supplies and a system interface module. This basic system supports a number of
monitor/module slots where a variety of system monitors and modules can be installed in order
to perform the machinery protection function required by the application.
Figure 2 - 1: Basic 3500 Safety Element Architecture
A SIL certified 3500 system will be made up of one or more certified monitors interacting with one
or more certified relay modules. Both the monitors and relay modules are designed specifically to
function within the 3500 architecture and communicate with each other, and cannot be directly
interfaced to external devices except as described above. The monitors and relay modules are
115M5936 Rev:- (05/16) 5
each certified independently to facilitate the flexibility of the system to be applied to a wide range
of safety instrumented function applications.
2.1 Rack Interface Monitor

The 3500/22M Transient Data Interface Module (TDI) performs the interface functions to the 3500
system. It is used to configure the monitors and modules in the system as well as provide a Rack
OK relay that provides an output of overall system health. Additionally, the module features a
configuration control keyswitch that can be used as a physical mechanism to lock the
configuration of the system to prevent unauthorized configuration changes. The TDI also
includes password configuration protection measures that can be used as an additional
software mechanism to prevent unauthorized configuration changes.
2.2 System Power Supplies

The 3500/15 System Power Supply accepts power from one of several possible power mains
sources, and conditions the input into regulated internal rack power supplies that support
internal power busses for the consumption of the monitors and modules installed in the system.
Each 3500/15 Power Supply is fully capable of supporting all 3500 system functions. When two
supplies are installed in a rack, the two supplies provide fully redundant system power mains
capability which will automatically switch out the support of rack power load in the event that
one supply or its power mains experiences a fault.
2.3 Monitors
The 3500 system monitors accept inputs from transducers in the field and condition the signal
into measurements useful for machinery protection. The monitor constantly compares the
measurements against configured alarm setpoints to generate alarm and channel OK statuses
that are broadcast onto system alarming networks. The monitors are installed in any of the
monitoring slots available in the system. Numerous SIL Certified monitors are available with the
3500 system, each providing different machinery protection capabilities. The different certified
monitors can be combined and/or duplicated to achieve the required safety instrumented
functionality.
A 3500 monitor is composed of a main card and an I/O module. The I/O module interfaces with
the transducers producing the machinery-related signals, and condition the signals for the
monitor main card. The main card is responsible for generating measurements from transducer
information and generating the alarm and status messages.
115M5936 Rev:- (05/16) 6
2.4 Relay Modules
The 3500 system relay modules consume the alarm and status information broadcast onto the
system alarming networks and constantly compares these messages against the configured
relay drive logic, to provide machinery protection trip output capability.
A 3500 relay module is a multi-channel module composed of a main card known as the relay
controller and a relay output module. The relay controller interfaces with the 3500 system
alarming network to process its configured relay drive logic and generate relay channel drive
signals. The relay I/O module accepts the relay drive signals from the controller and contains the
relay devices which provide the machinery trip contacts.
Each channel provides independent “Alarm Drive Logic” functionality which allows the user to
develop complex logic strings using Boolean (AND and OR) logic elements. The logic acts on the
alarm states (alert, danger) and validity states (Not OK) generated by monitors in the system
which are available from the system alarming networks. Each channel’s logic string drives its own
relay output which is intended to be used as a machinery trip output.
The module’s fundamental safety function is the relay output contact state change.
The module is configured using the 3500 Rack Configuration Software. All software configuration
options and logic parameters available, are valid for use supporting the safety function without
restriction. These parameters can be selected and arranged to suit the specific application
requirements.
The Relay I/O contains three output contacts: Armature (ARM), Normally Open (NO), and Normally
Closed (NC), which refer to the state of the contacts when the relay coils are de-energized. Also,
each channel is independently configurable for Normally Energized (NE) or Normally De-
energized (NDE) by means of DIP switches located on the back of the I/O module. The NE/NDE
state refers to the state of the relay drive coil under normal (non-emergency) conditions.
2.4.1 3500/32M_SIL 4-Channel Relay Module

The 3500/32M_SIL is a four channel variant of the relay module which can be applied in either a
one-out-of-one (1oo1), or a one-out-of-two (1oo2) architecture. A single path approach can be
used to achieve a SIL 1 capable 1oo1 solution, while a dual path (redundant) approach can be
used to achieve a SIL 2 capable, 1oo2 solution. Section 4.2 outlines the specific details that must
be adhered to in order to correctly apply the relay module to achieve the two different SIL
capable solutions.
115M5936 Rev:- (05/16) 7
Refer to the 3500/32 and 3500/32M Operation and Maintenance Manual (Part Number 129771-01)
configuration section on how to properly configure the module using the 3500 Rack
Configuration Software. For proper field wiring installation diagrams refer to the appropriate
module section in of the 3500 System Field Wiring diagram package (Part Number 130432-01) for
further information.
1. Relay module
2. I/O module
3. Status LEDs
4. Relay channel LEDs
5. Relay Contacts
6. Relay mode selection switch
Figure 2 - 2: 3500/32M_SIL Hardware Identification
115M5936 Rev:- (05/16) 8
Table 2 - 1: SIL Certified 3500/32M_SIL Relay Modules
Part No. Output Module (AXX) Agency Approval Option (BXX)
00 - None
3500/32M_SIL1 –A01 –BXX 01 - 4-Channel Relay
01 - CSA/NRTL/C (Class 1, Div 2)
3500/32M_SIL2 –A01 –BXX Output Module
02 - ATEX.CSA (Class 1, Zone 2)
Table 2 - 2: 3500/32M_SIL Spare Part Numbers
Spare part number Description Hardware Revision Firmware Revision
3500/32M_SIL1 3500/32M SIL1 4-Channel Relay Module B 3.0
3500/32M_SIL2 3500/32M SIL2 4-Channel Relay Module B 3.0
3500/32_SIL1-A01-BXX 3500/32 SIL1 4-Channel Relay I/O Module AA N/A
3500/32_SIL2-A01-BXX 3500/32 SIL2 4-Channel Relay I/O Module AA N/A
2.4.2 3500/33_SIL 16-Channel Relay Module

The 3500/33_SIL is a sixteen channel variant of the relay module which can be applied in either a
one-out-of-one (1oo1), or a one-out-of-two (1oo2) architecture. A single path approach can be
used to achieve a SIL 1 capable 1oo1 solution, while a dual path (redundant) approach can be
used to achieve a SIL 2 capable, 1oo2 solution. Section 4.2 outlines the specific details that must
be adhered to in order to correctly apply the relay module to achieve the two different SIL
capable solutions.
Refer to the 3500/33 Operation and Maintenance Manual (Part Number 162291-01) configuration
section on how to properly configure the module using the 3500 Rack Configuration Software.
For proper field wiring installation diagrams refer to the appropriate module section in the 3500
System Field Wiring diagram package (Part Number 130432-01).
The 3500/33_SIL relay module provides two options for the Relay I/O. It can be paired with either
the standard I/O (3500/33-A01-BXX) or the “failsafe” I/O (3500/33-A02-BXX). The failsafe Relay I/O
Module provides fail-safe behavior under a number of relay module fault conditions as described
below:
l Removal of the main relay controller module from the front of the 3500 rack will cause all
relays on its associated failsafe relay I/O module to go to the in alarm state.
115M5936 Rev:- (05/16) 9
l When used with a failsafe Relay I/O module the microprocessor on the main relay
controller module will drive the relays to the in-alarm state in the event that it detects a fatal
error during its diagnostic checks or if a microprocessor execution exception occurs.
1. Relay module
2. I/O module
3. Status LEDs
4. Relay channel LEDs
5. Relay Contacts
6. Relay mode selection switch
Figure 2 - 3: 3500/33_SIL Hardware Identification

Table 2 - 3: SIL Certified 3500/33_SIL Relay Modules
Agency Approval Option

Part No. Output Module (AXX)
(BXX)
00 - None
01 - 16-Channel Relay Output Module 01 - CSA/NRTL/C (Class 1, Div
3500/33_SIL1 –AXX –BXX
02 - 16-Channel Failsafe Relay Output 2)
3500/33_SIL2 –AXX –BXX
Module 02 - ATEX/CSA (Class 1, Zone
2)
115M5936 Rev:- (05/16) 10
Table 2 - 4: 3500/33_SIL Spare Part Numbers
Hardware Firmware
Spare part number Description
Revision Revision
3500/33_SIL1 3500/33 SIL1 16-Channel Relay Module E 3.0
3500/33_SIL2 3500/33 SIL2 16-Channel Relay Module E 3.0
3500/33_SIL1-A01-
3500/33 SIL1 16-Channel I/O Module M N/A
BXX
3500/33_SIL2-A01-
3500/33 SIL1 16-Channel I/O Module M N/A
BXX
3500/33_SIL1-A02- 3500/33 SIL1 16-Channel Failsafe I/O

D N/A
BXX Module
3500/33_SIL2-A02- 3500/33 SIL1 16-Channel Failsafe I/O

D N/A
BXX Module
115M5936 Rev:- (05/16) 11
3. Constraints and SIL Requirements

The following are requirements and recommendations for the 3500/32M_SIL and 3500/33_SIL
Functional Safety Certified products that must be considered in order for the product to be
integrated into a safety-related system. These requirements and recommendations should be
observed in order to achieve the necessary performance of the system and prevent systematic
failures of the compliant product. For detailed information on conditions of use, refer to the
certificates and test reports, contact Bently Nevada technical support, or visit
http://www.GEmeasurement.com.
3.1 Skills Required to Commission and Maintain SIL Monitors

The 3500 system is highly configurable and flexible to accommodate a large number of
machinery monitoring and protection applications. Due to this high level of configurability, only
individuals that are familiar with the installation, operation and maintenance of the 3500 platform
should configure, commission, and maintain the 3500 System.
3.2 SIL 1 Requirements

TÜV Rheinland of North America has determined that the 3500 Vibration Protection System
3500/32M_SIL and 3500/33_SIL Relay Modules meet the requirements for Safety Integrity Level 1
and 2 according to international standard IEC 61508. It can be used as a machinery protection
system according to API 670 under the observance of the information in the Operating and
Maintenance Manual and as described below.
3.2.1 Ordering requirements:

l When ordering a SIL certified 3500/32M module, the part number that is ordered must be
3500/32M_SIL1, or 3500/32M_SIL2.
l When ordering a SIL certified 3500/33 module, the part number that is ordered must be
3500/33_SIL1 or 3500/33_SIL2.
l Only those components contained within the TUV certified configurations can be used
within a SIL. Refer to tables 2-1 and 2-3, or contact your local representative for details.
3.2.2 Hardware Requirements:

l The 3500/32M_SIL or 3500/33_SIL must be installed in a 3500 Rack that has a 3500/22 TDI
Rack Interface Module and at least one SIL certified monitor card and I/O such as the
115M5936 Rev:- (05/16) 12
3500/40M_SIL or 3500/42M_SIL.
l The 3500 System that contains the 3500/32M_SIL or 3500/33_SIL modules must be
supported by redundant 3500/15 Power Supplies.
l The system program keyswitch on the 3500/22M TDI must be set to the "RUN" position after
the 3500/32M_SIL or 3500/33_SIL Relay Modules are configured, and the system
commissioned.
l Removal of any component of the 3500 system that is part of the critical safety path will
require a full proof test of the SIL system.
l The output relays must be configured for normally energized at the non-alarm condition
(de-energize to trip).
l The wiring of the relay contacts must be such that the output circuit has continuity under
non-alarm conditions, with the loss of circuit continuity indicating the unsafe state (the
external circuit is de-energize to trip). Note that this is distinct and different from the relay
drive coil normally energize/normally de-energized configuration.
l The system OK relay on the 3500/22M TDI must continuously monitored by an automated
system to provide detection of system faults.
l The 3500/32M_SIL has a maximum contact rating of 2A and 30V.
l The 3500/33_SIL has a maximum contact rating of 5A and 30V.
l The 3500/32M_SIL and 3500/33_SIL are considered to be a system operating in low
demand mode.
3.2.3 Software Requirements:

l The relay drive logic that supports the safety function, must accept only alarming
parameters from SIL Certified Monitors.
l The monitoring card(s) used with the 3500/32M_SIL or 3500/33_SIL must be installed and
configured per the applicable monitor’s SIL safety manual.
l The system’s configuration must be password protected.
l All relay module software configuration options and logic parameters available are valid
for use supporting the safety function without restriction.
l After the relay module has had the configuration downloaded to it, the module
configuration must be uploaded back to the host computer and the specified settings
compared to verify the configuration was correctly received.
l The validation tests from the product manual must be performed. The behavior of the
safety system in reference to particular failure conditions of the monitors (e.g. NOT OK
status, no neuron communication) shall be evaluated at the system level.
115M5936 Rev:- (05/16) 13
3.3 Recommendations
Bently Nevada, Inc. recommends having GE Bently Nevada Services inspect the components and
system during validation/commissioning for proper installation, configuration and usage.
115M5936 Rev:- (05/16) 14
4. Functional Specifications
Each channel provides independent “Alarm Drive Logic” functionality which allows the user to
develop complex logic strings using Boolean (AND and OR) logic elements. The logic acts on the
alarm states (alert, danger) and validity states (Not OK) generated by monitors in the system
which are available from the system alarming networks. Each channel’s logic string drives its own
relay output intended to be used as a machinery trip output.
Associated safety related elements such as Proximitors* and other 3500 Monitors (e.g. 3500/7X),
have been independently assessed by the test institute and the results are documented under
their individual test reports.
4.1 Systematic Capability

The 3500/32M_SIL and 3500/33_SIL techniques and measures to avoid and control systematic
failures during the safety lifecycle phases were inspected by TÜV Rheinland, which resulted in a
systematic capability of SIL 2 in accordance to IEC 61508: 2010, route 1S.
4.2 Architectural/Random Constraints, Overview

The 3500 SIL certified relay modules are available in four-channel and sixteen-channel variants,
both of which are capable of being configured in 1oo1 or 1oo2 architectures to achieve a SIL 1
capable or a SIL 2 capable element, respectively. The following sections outline the architectural
constraints for three different architecture configurations:
l 1oo1 - (SIL 1 capable)

l 1oo2 with redundant relay paths - (SIL 2 capable)
l 1oo2 with redundant controller and relay paths - (SIL 2 capable)
4.2.1 Architectural/ Random Constraints, 1oo1 Configuration

The calculation of the 3500/32M_SIL1 and 3500/33_SIL1 Relay Modules safety relevant
parameters has shown that the requirements of SIL 1 to IEC 61508: 2010 are fulfilled in a 1oo1
configuration.
The component level FMEDA was carried out by TÜV Rheinland under consideration to the
requirements of IEC 61508, parts 1-7:2010. Component failure rates were based on SN 29500, with
a maximum ambient temperature of 65°C.
The safety related parameters are as follows:
115M5936 Rev:- (05/16) 15
l The relay channel must be configured for de-energize to trip.
l The safety-related circuit must be set up such that the opening of the relay contacts
activates the safety function (de-energize circuit to trip) as shown in figure 4-1.
l Average probability of a dangerous failure on demand (PFD) < 10 E-1.
l The 3500/32M_SIL and 3500/33_SIL modules are considered to be a system operating in a
low demand mode.
l The 3500/32M_SIL and 3500/33_SIL modules have a hardware safety integrity route of 1H.
l The 3500/32M_SIL and 3500/33_SIL modules have a systematic safety Integrity route of 1S.
l The rated life time of the 3500/32M_SIL and 3500/33_SIL modules is 10 years.
l The 3500/32M_SIL and 3500/32_SIL Relay Controller Module are Type B safety related
elements with a Safe Failure Fraction (SFF) of 60% to <90%.
l The 3500/32M_SIL and 3500/32_SIL Relay Output Modules are Type A safety related
elements with a Safe Failure Fraction (SFF) of <60%.
l The 3500/32M_SIL and 3500/33_SIL modules have a Hardware Fault Tolerance (HFT) of 0
when used in a 1oo1 configuration.
l The MTTR and MRT for the 3500/32M_SIL and 3500/33_SIL modules is 168 hours or 1
week**.
**MTTR and MRT were assigned as 168 hours for the purposes of generating the PFDAVE
calculation. This figure may be adjusted to suit application specific considerations as long as the
specific value is also used to adjust the PFDAVE calculation specific to the safety-related
installation.
Figure 4 - 1: 1oo1 Relay Configuration
As shown in the safety block diagram, Figure 4-2, the 3500/32M and 3500/33 Relay Controller
Modules are classified as Type B devices, and the 3500/32 and 3500/33 Relay Output Modules are
115M5936 Rev:- (05/16) 16
Type A. The failure rates when used in the 1oo1 configuration are shown in Table 4-1. These
failure rates are based on the 1oo1 safety block diagram in Figure 4-2.
Figure 4 - 2: Safety block diagram, 1oo1 configuration

Table 4 - 1: 1oo1 Configuration Failure Rates
1oo1 Relay Failure Modes Controller Module Relay Module
Safe failure rate λ 451 FIT 585 FIT

s
Dangerous failure rate λ 397 FIT 568 FIT
d
Dangerous undetected failure rate λ 82 FIT 498 FIT
du
The following values were calculated by TÜV Rheinland of North America for the 3500/32M and
3500/33.
The review of the SFF (safe failure fraction) requirements in reference to IEC 61508, parts 1-7:2010
has shown that the Relay Controller Module achieves 60% to <90% and the Relay I/O Module
when used in the 1oo1 configuration shown in Figure 4-2 is <60%.
PFDAVG = 2.7 E-3, with the following assumptions:
l 1 year proof test interval

l MTTR = 168 hours
4.2.2 Architectural/ Random Constraints, 1oo2 Configuration with

Redundant Relay Paths
parameters has shown that the requirements of SIL 2 to 61508: 2010 are fulfilled in a redundant,
1oo2 configuration, as shown in Figure 4-3.
requirements of IEC 61508, parts 1-7:2010. Component failure rates were based from SN 29500,
with a maximum temperature of 65°C.
115M5936 Rev:- (05/16) 17
l Average Probability of a dangerous failure on demand (PFD) < 10 E-2.
low demand mode.
l The 3500/32M_SIL and 3500/33_SIL Relay Controller Modules, and a Relay Output Modules
are Type B safety related elements with a Safe Failure Fraction (SFF) of >90%, with a
Hardware Fault Tolerance (HFT) of 0.
elements with a Safe Failure Fraction (SFF) of <60%, with a Hardware Fault Tolerance (HFT)
of 1 when used in a 1oo2 configuration. The signal path of an individual relay channel
contained on the Relay Output Module is a Type A safety related element with a βD =5%,
and β =10%
week**.
installation.
115M5936 Rev:- (05/16) 18
As shown in the 1oo2 safety block diagram, Figure 4-4, the 3500/32M and 3500/33 Relay
Controller Modules are classified as Type B devices, and the 3500/32 and 3500/33 Relay Output
Modules are Type A. The failure rates when used in the 1oo2 configuration are shown in Table 4-
2. These failure rates are based on the 1oo2 safety block diagram in Figure 4-4.
Figure 4 - 4: Safety block diagram, 1oo2 configuration -

redundant relay paths
115M5936 Rev:- (05/16) 19
Table 4 - 2: 1oo2 Configuration Failure Rates
/32M and /33 Internal 1oo2 Relay Failure Modes Controller Module Relay Module

s Common
s Redundant
d Common
d Redundant
du Common
du Redundant
3500/33.

l MTTR = 168 hours
l βD =5%, and β =10%
4.2.3 Architectural/Random Constraints, 1oo2 Configuration with

Redundant Controller and Relay Paths
parameters has shown that the requirements of SIL 2 to 61508: 2010 are fulfilled in a redundant,
1oo2 configuration, as shown in Figure 4-5.
requirements of IEC 61508, parts 1-7:2010. Component failure rates were based from SN 29500,
with a maximum temperature of 65°C.

l Average Probability of a dangerous failure on demand (PFD) < 10 E-2.
low demand mode.
115M5936 Rev:- (05/16) 20
l The 3500/32M_SIL and 3500/33_SIL Relay Controller Modules are Type B safety related
elements with a Safe Failure Fraction (SFF) of 60% to <90%. The Relay Controller Module has
a βD =5%, and β =10%.
elements with a Safe Failure Fraction (SFF) of <60%. The Relay Output Module has a βD =5%,
and β =10%.
l The 3500/32M_SIL and 3500/33_SIL modules have a Hardware Fault Tolerance (HFT) of 1
when used in a 1oo2 configuration.
week**.
installation.
115M5936 Rev:- (05/16) 21
As shown in the 1oo2 safety block diagram, Figure 4-6, the 3500/32M and 3500/33 Relay
Controller Modules are classified as Type B devices, and the 3500/32 and 3500/33 Relay Output
Modules are Type A. The failure rates when used in the 1oo2 configuration are shown in Table 4-
3. These failure rates are based on the 1oo2 safety block diagram in Figure 4-6.
Figure 4 - 6: Safety block diagram, 1oo2 configuration -

redundant controller and relay paths
Table 4 - 3: 1oo2 Configuration Failure Rates***
/32M and /33 Internal 1oo2 Relay Failure Modes Controller Module Relay Module

sCommon
d Common
du Common
***λvalues listed are for a single path of the redundant system.
3500/33.

l MTTR = 168 hours
l βD =5%, and β =10%
115M5936 Rev:- (05/16) 22
5. Failure Modes
This section covers the failure modes of the 3500/32M_SIL and 3500/33_SIL relay modules and
their internal diagnostics system. The estimated failure rate for each of these failure modes are
given after each subsection of the corresponding failure mode.
The failure rates are driven by the following assumptions:
l Failure rates are based on Siemens standard SN 29500 and the outlined maximum
temperature limits shown under the user manual of the relevant component.
l The failure rate is constant over time.
l The listed failure rates are in Failure in Time (FIT) = fit = [10-9 1/h].
5.1 Failure modes of the 3500/32M_SIL and 3500/33_SIL

Modules
The specific failure modes of the 3500/32M_SIL and 3500/33_SIL modules are detailed in the
FMEDA report, which is included in the SIL report which is available from GE Bently Nevada.
5.2 Failure modes that are not detected by internal

diagnostics
When a failure mode occurs in a 3500/32M_SIL and 3500/33_SIL module that is not capable of
being detected by the internal diagnostics of the module, the condition is not reported, there is no
adjustment of the relay output states, and the Rack OK relay does not change state. This is the
case whether the failure is safe or dangerous.
5.3 Failure modes that are detected by internal diagnostics

The 3500/32M_SIL and 3500/33_SIL modules feature internal diagnostics capabilities. When any
failure is detected by the diagnostics, the module responds by annunciating the condition, and
driving the Rack OK relay on the 3500/22M TDI to the “Not OK” state. In cases where a fault occurs
that prevents the module from conducting its internal diagnostics and communicating with
other system components, the 3500/22M TDI Module is capable of detecting the loss of
communications, and responds by driving the Rack OK relay to the “Not OK” state.
When faults are detected by the module, the 3500/22M TDI records the failures in the 3500 System
Event List. Refer to the "System Event List Messages" sections in the 3500/32M operation manual
115M5936 Rev:- (05/16) 23
(Part number 129771-01) or the 3500/33 operation manual (part number 162291-01) for a full list of
failure codes that are detected by the internal diagnostic system.
5.3.1 Diagnostic test interval

The cycle interval between internal diagnostic checking is 1 hour maximum. In the vast majority
of cases the interval is far less. The specified one hour interval is based on the fact that all of the
diagnostics checks may take up to 1 hour to complete under worst-case conditions.
5.3.2 System Outputs

For any failure modes that are detected by the 3500/32M_SIL and 3500/33_SIL monitors by the
internal diagnostic system, the Rack OK relay will drive to a NOT OK state.
5.3.3 LED Fault Conditions

Refer to the 3500/33 operation manual (Part number 162291-01) or the 3500/32M operation
manual (part number 129771-01) for a list of the LED behavior under fault conditions.
5.4 Failure modes of the diagnostics

The failure modes of the 3500/32M_SIL and 3500/33_SIL diagnostic system are in the FMEDA
report, which is included in the SIL report which is available from GE Bently Nevada.
5.5 External diagnostics

The 3500/32M_SIL and 3500/33_SIL are designed to be used in a 3500 system that includes at
least one SIL certified monitor installed and used in conjunction with the SIL certified relay module
(s). As described in sections 5.2 and 5.3, in addition to providing safety relay output functionality to
the safety-related system, the 3500/22M TDI Module also provides a measure of external
diagnostic capability to the module in the event that the monitor is rendered unable to
communicate to the other system components. This external diagnostic functionality is
established by simply installing the relay module in a properly constructed SIL 3500 system .
The 3500 system supporting the SIL certified monitor must have a 3500/22M TDI module installed.
The Rack interface monitor performs diagnostics on all the monitors and I/O's installed in the
Rack which are separate from the individual monitor internal diagnostics. When the Rack
Interface Monitor senses a failure mode of one of the installed monitors, it changes the Rack OK
relay to the Not OK state. Refer to the FMEDA report, which is available from GE Bently Nevada
under the SIL Report, for all failure modes that drive the Rack OK Relay.
115M5936 Rev:- (05/16) 24
6. Periodic Proof Test

The circuit boards and components inside 3500 modules cannot be repaired in the field. 3500
rack maintenance consists of testing module channels to verify that they are operating correctly.
Monitors and modules that are not operating correctly should be replaced with a spare.
When performed properly, you may install the 3500/32M or 3500/33 controller module into or
remove the module from the rack while power is applied to the rack, except when the rack is in a
hazardous area. A hazardous area is defined by document BS EN 60079-0:2012 as an area in
which an explosive atmosphere is present, or may be expected to be present, in quantities such
as to require special precautions for the construction, installation and use of electrical apparatus.
Refer to the Rack Installation and Maintenance Manual (part number 129766-01) for the proper
procedure.
6.1 Choosing a Periodic Proof Test Interval

The proof test coverage provided by the internal diagnostic functionality of the 3500/32M_SIL
and 3500/33_SIL monitors is 93%. Those dangerous failures that fall outside of the monitor’s
diagnostic capability are considered dangerous undetected failures which must be detected as
part of periodic proof test activities.
GE Bently Nevada Recommends a periodic proof test interval of 1 year but by using the PFDAVE
equation from 61508-6 that is appropriate for the specific safety-related system, the effect on the
PFDAVE value can be determined for longer or shorter periodic proof test intervals.
6.2 Periodic Proof test guide

The test setup for verifying a Relay Module involves making connections to the monitor channels
involved in the relay drive logic in order to simulate the monitor inputs. The inputs will be adjusted
to exercise the SIF’s relay logic, and verify that each of the relay contacts on the Relay Output
Module are performing as intended. Note that if redundant relays are used, as shown in Figure 4-
3 or 4-5, it is important to verify both sets of contacts. Reference the individual operation and
maintenance manuals for each monitor used in the SIF’s relay drive logic for the monitor-specific
verification details.
115M5936 Rev:- (05/16) 25
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3500/32M_SIL and /33_SIL Relay

The information contained in this document is subject to change without notice.

Bently Nevada, Proximitor

The following are trademarks of the legal entities cited:

Printed in USA. Uncontrolled when transmitted electronically.

1631 Bently Parkway South

115M5936 Rev:- (05/16) ii

3500 Field Wiring Diagram Package (part number 130432-01)

3500/22M TDI Operation and Maintenance Manual (part number 161580-01)

3500/33 16-Channel Relay Module Manual (part number 162291-01)

3500/33 16-Channel Relay Module Data Sheet (part number 162301-01)

3500 System: Functional Safety Data Sheet (part number 162242-01)

Product Disposal Statement

115M5936 Rev:- (05/16) iii

115M5936 Rev:- (05/16) iv

5.3 Failure modes that are detected by internal diagnostics 23

115M5936 Rev:- (05/16) v

115M5936 Rev:- (05/16) 1

115M5936 Rev:- (05/16) 2

IEC 61508 requirements (part 2 annex D) Reference

D2.1 c) constraints on the use of the compliant item and/or assumptions

D2.2 a) the failure modes of the compliant item due to random

D2.2 d) the failure modes of the diagnostics, internal to the compliant

Failure rate for D.2.2 c) Section 4

D2.2 f) for every failure mode in c) that is detected by diagnostics

D2.2 h) any periodic proof test and/or maintenance requirements Section 6

D2.2 i) for those failure modes, in respect of a specified function, that

D2.2 j) the hardware fault tolerance Section 4.2

D2.2 k) the classification as type A or type B of that part of the compliant

D.2.3 a) The systematic capability of the complaint item or that part of

D.2.3 b) Any instructions or constraints relating to the application of the

115M5936 Rev:- (05/16) 3

TÜV Certificate number 968/EZ 323.02/12 dated 2012-08-29

TÜV Certificate number 968/EZ 323.03/14 dated 2014-05-15

Schematic diagram 3500/33 16-Channel Relay IO Board, Dwg. No: 149993

Schematic diagram 3500/32 4-Channel Relay IO Board, Dwg. No: 125721

Statement of Compliance, BN26744C-18

System test procedures, No: 158792, Rev. NC, 28 Nov 1995

115M5936 Rev:- (05/16) 4

Figure 2 - 1: Basic 3500 Safety Element Architecture

115M5936 Rev:- (05/16) 5

2.1 Rack Interface Monitor

2.2 System Power Supplies

115M5936 Rev:- (05/16) 6

2.4.1 3500/32M_SIL 4-Channel Relay Module

115M5936 Rev:- (05/16) 7

Figure 2 - 2: 3500/32M_SIL Hardware Identification

115M5936 Rev:- (05/16) 8

Part No. Output Module (AXX) Agency Approval Option (BXX)

Table 2 - 2: 3500/32M_SIL Spare Part Numbers

Spare part number Description Hardware Revision Firmware Revision

3500/32M_SIL1 3500/32M SIL1 4-Channel Relay Module B 3.0

3500/32M_SIL2 3500/32M SIL2 4-Channel Relay Module B 3.0

3500/32_SIL1-A01-BXX 3500/32 SIL1 4-Channel Relay I/O Module AA N/A

3500/32_SIL2-A01-BXX 3500/32 SIL2 4-Channel Relay I/O Module AA N/A