HB Sil Sa1 Sa2 Am1 SFC en
HB Sil Sa1 Sa2 Am1 SFC en
HB Sil Sa1 Sa2 Am1 SFC en
Reference documents:
●
exida report no. AUMA 10-12-035 R005E
●
Operation instructions (Assembly, operation, commissioning) for actuator
Reference documents are available on the Internet at: http://www.auma.com.
2
Multi-turn actuators
with AM 01.1/AM 02.1/AMExC01.1 Terminology
1. Terminology
Information sources ● IEC 61508-4, Functional safety of electrical/electronic/programmable electronic
safety-related systems – Part 4: Definitions and abbreviations
● IEC 61511-1, Functional safety - Safety instrumented systems for the process
industry sector – Part 1: Framework, definitions, system, hardware and software
requirements
1.1. Abbreviations and concepts
To evaluate safety functions, the lambda values or the PFD value (Probability of
Dangerous Failure on Demand) and the SFF value (Safe Failure Fraction) are the
main requirements. Further figures are required to assess the individual components.
These figures are explained in the table below.
Safety function Function to be implemented by a safety-related system for risk reduction with the
objective to achieve or maintain a safe state for the plant/equipment with respect to
a specific dangerous event.
Safety instrumented Function with specified safety integrity level (SIL) to achieve functional safety.
function (SIF)
Safety instrumented Safety instrumented system for executing a single or several safety instrumented
system (SIS) functions. An SIS consists of sensor(s), logic system and actuator(s).
Safety-related system A safety-related system includes all factors (hardware, software, human factors)
necessary to implement one or several safety functions. Consequently failures of
safety function would result in a significant increase in safety risks for people and/or
the environment.
A safety-related system can comprise stand-alone systems dedicated to perform a
particular safety function or can be integrated into a plant.
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Multi-turn actuators
Terminology with AM 01.1/AM 02.1/AMExC01.1
Proof test Periodic test performed to detect dangerous hidden failures in a safety-related system
so that, if necessary, a repair can restore the system to an "as new" condition or as
close as practical to this condition.
MTTR (Mean Time To Mean time to restoration once a failure has occurred. Indicates the expected mean
Restoration) time to achieve restoration of the system. It is therefore an important parameter for
system availability. The time for detecting the failure, planning tasks as well as
operating resources is also included. It should be reduced to a minimum.
4
Multi-turn actuators
with AM 01.1/AM 02.1/AMExC01.1 Application and validity
Hardware, software and configuration of actuator and actuator controls must not be
modified without prior written consent by AUMA. Unauthorised modifications may
have a negative impact on both safety figures and SIL capability of the products.
Information In applications with requirements on functional safety, only AUMA actuator controls
and actuators in SFC or SIL version may be used. SFC stands for “Safety Figure
Calculated”. This designation identifies AUMA products for which safety figures were
calculated on the basis of FMEDA from field data and generic data (for detailed in-
formation refer to <Determination of the figures>).
AUMA actuator controls and actuators in SFC version can among others be identified
from the letters "SFC" following the type designation on the name plate.
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Multi-turn actuators
Architecture, configuration and applications with AM 01.1/AM 02.1/AMExC01.1
Incorrect actuator architecture can lead to device damage within the safety-
related system!
Possible consequences: Valve damage, motor overheating, contactor seizure,
damage to the electronics, heating up or damage to cables.
→ The actuator technical data must imperatively be observed when selecting the
actuator.
→ Sufficient reserves have to be provided to ensure that actuators are capable of
reliably opening or closing the valve even in the event of an accident or under-
voltage.
Information For the “Safe end position feedback” safety function, heed that signalling is made
via mechanical switches. Since these elements have an unavoidable hysteresis, the
actuator slightly leaves the end position before the end position signal is deleted.
Consequently, there is a marginal range of actuator positions to the safety position,
for which the end position is still signalled although the actuator has already left the
end position during operation from safety position. If the range in question is ap-
proached from the opposite direction, this limitation does not apply. In general this
range is relatively small. However, for unfavourable configurations (low number of
turns per stroke), this range can amount to more than 10 % of the total stroke.
Should, within the framework of unfavourable conditions, the effect described above
represent an unacceptable limitation for the safety function, we recommend evaluating
both limit and torque switches for the end position feedback.
Power supply
Information An exact setting of torque and end position switches for the end positions is imperat-
ively required to ensure correct function of “Safe end position feedback”. For setting
details related to the respective switches, please refer to operation instructions.
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Multi-turn actuators
with AM 01.1/AM 02.1/AMExC01.1 Architecture, configuration and applications
Table 3: Overview self-locking for AUMA actuators (at the time of printing of this document)
Type Output speed Self-locking
50 Hz 60 Hz
SA 07.2 – SA 16.2 ≤ 90 rpm ≤ 108 rpm Self-locking
SAR 07.2 – SAR 16.2 ≥ 125 rpm ≥ 150 rpm NOT self-locking
SAEx 07.2 – SAEx 16.2
SAREx 07.2 – SAREx 16.2
SA 25.1 – SA 30.1 ≤ 90 rpm ≤ 108 rpm Self-locking
SAR 25.1 – SAR 30.1 ≥ 125 rpm ≥ 150 rpm NOT self-locking
SAEx 25.1 – SAEx 30.1
SAREx 25.1 – SAREx 30.1
SA 35.1 ≤ 22 rpm ≤ 26 rpm Self-locking
SAEx 35.1 ≥ 32 rpm ≥ 38 rpm NOT self-locking
SA 40.1 ≤ 22 rpm ≤ 26 rpm Self-locking
SAEx 40.1 ≥ 32 rpm ≥ 38 rpm NOT self-locking
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Multi-turn actuators
Architecture, configuration and applications with AM 01.1/AM 02.1/AMExC01.1
Table 4:
Classes A and B Class C (Modulation)
Contact material Silver Gold Silver Silver Gold Gold
Maximum electrical load 30 V/30 mA 250 V AC/5 A 30 V/30 mA 50 V/400 mA
Number of permissible cycles of end position < 20,000 < 20,000 < 100,000 < 20,000 < 100,000 < 20,000
switch as well as cycles according to EN 15714-
2:2010
HFT is 0.
Only flanges of F07 or FA 07 sizes or larger may be used for valve attachment.
For “safe end position feedback”, the actuator can be considered as type A device.
Safety figures
The safety figures relevant for the product supplied as well as potential further
restrictions are indicated on the declaration of incorporation. The declaration of
incorporation is specific for each order and directly supplied with the order.
3.6. Applications (environmental conditions)
When specifying and using the actuators within safety instrumented systems, make
sure that the permissible service conditions and the EMC requirements by the
peripheral devices are met. Service conditions are indicated in the technical data
sheets:
● Enclosure protection
● Corrosion protection
● Ambient temperature
● Vibration resistance
If the actual ambient temperatures exceed an average of +40 °C, the lambda values
have to be incremented by a safety factor. For an average temperature of +60 °C,
this factor is specified to 2.5.
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Multi-turn actuators
with AM 01.1/AM 02.1/AMExC01.1 Safety instrumented systems and safety functions
3) Please note that safety figures only include the components of the actuator . Further components
(e.g. integrity of external controls, gearboxes, valve shaft, other valve components....) are not
considered with the AUMA safety figures related to this product
9
Multi-turn actuators
Installation, commissioning and operation with AM 01.1/AM 02.1/AMExC01.1
5.1. Installation
General installation tasks (assembly, electrical connection) have to be performed
according to the operation instructions pertaining to the device and the enclosed
order-specific wiring diagram.
Figure 2: Wiring diagram example with safe end position feedback
5.2. Commissioning
The operation instructions pertaining to the device must be observed for general
commissioning.
After commissioning, the safe actuator function must be verified.
5.3. Operation
Regular maintenance and device checks in the Tproof intervals as defined by the
plant operator are the basis for safe operation.
The operation instructions pertaining to the device must be observed for operation.
5.4. Lifetime
Actuator lifetime is described in the technical data sheets or the operation instructions.
Safety-related figures are valid for the cycles or modulating steps defined in the
technical data specifications and for typical periods of up to 10 years (the criterion
achieved first is valid). After this period, the probability of failure increases.
Extending this period is basically feasible in many cases “provided both manufacturer
and operator introduce respective actions” in compliance with footnote N3 of NOTE
3 of the German version of IEC 61508-2:2010 7.4.9.5 b). This is the responsibility
of the operator who will have to take appropriate and suitable measures. Please
contact us if you need support in identifying suitable measures.
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Multi-turn actuators
with AM 01.1/AM 02.1/AMExC01.1 Installation, commissioning and operation
5.5. Decommissioning
When decommissioning an actuator with safety functions, the following must be
observed:
● Impact of decommissioning on relevant devices, equipment or other work must
be evaluated.
● Safety and warning instructions contained in the actuator operation instructions
must be met.
● Decommissioning must be carried out exclusively by suitably qualified personnel.
● Decommissioning must be recorded in compliance with regular requirements.
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Multi-turn actuators
Tests and maintenance with AM 01.1/AM 02.1/AMExC01.1
All safety functions within a safety equipment must be checked for perfect functionality
and safety at appropriate intervals. The intervals for safety equipment checks are to
be defined by the plant operator.
The plant operator has to establish a safety schedule for the entire safety lifecycle
of the SIS to avoid systematic faults. Policies and strategies for achieving safety as
well as different activities during the safety life cycle should be defined.
6.2. Proof test (verification of safe actuator function)
The proof test serves the purpose to verify the safety-related functions of the actuator
and actuator controls.
Proof tests shall reveal dangerous faults which might remain undetected until a safety
function is started and consequently result in a potential danger.
For checking the safety-related function, the output of safe end position feedback is
appropriately checked.
Information All installed and used safety functions within the actuator must be checked and all
test steps performed in compliance with the pertaining checklists.
Intervals:
A proof test interval describes the time between two proof tests. Functionality must
be checked at appropriate intervals. The intervals are to be defined by the plant
operator.
In any case, the safety-related functions must be checked after commissioning and
following any maintenance work or repair as well as during the Tproof intervals defined
in safety assessment.
The actuator system has to be subjected to a visual inspection first. The system
should be checked for outside damage and corrosion. Furthermore, the electrical
and mechanical connections should be checked and the actuator inspected for
unusual noises while operating the actuator at least a complete travel from CLOSED
to OPEN and back.
6.2.2. Review and validation of the “Safe end position signal” safety function
Test sequence (check- 1. Operate actuator to end position OPEN – Is the end position OPEN signalled
list) via Safe end position signal?
2. Unseat actuator out of end position OPEN – Is the safe end position signal
OPEN cancelled?
3. Operate actuator again to end position OPEN – Is the end position OPEN sig-
nalled again via Safe end position signal?
4. Operate actuator to end position CLOSED – Is the end position CLOSED sig-
nalled via Safe end position signal?
5. Unseat actuator out of end position CLOSED – Is the safe end position signal
CLOSED cancelled?
6. Operate actuator again to end position CLOSED – Is the end position CLOSED
signalled again via Safe end position signal?
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Multi-turn actuators
with AM 01.1/AM 02.1/AMExC01.1 Tests and maintenance
7. During the complete procedure, no fault signal at collective fault signal output
contact K9?
8. Separately check collective fault signal output contact K9 – Reaction to simulated
fault?
Information: The collective fault output contact K9 can be activated via manual
torque switch test using the test buttons. Refer to the relevant chapter in the
operation instructions.
6.3. Diagnostics via Partial Valve Stroke Test (PVST) / Reaction Monitoring (RM)
Regular actuator diagnostics is required using diagnostics facilities. Diagnostics
should be performed at least 10 times more often than the proof test. This diagnostic
comprises a specific actuator movement relating to an appropriate travel and
subsequent evaluation whether the actuator reacts as expected. The individual safety
functions are described in more detail below.
The actuator movement required for diagnostics can be initiated on purpose (PVST).
If the actuator is operated regularly by conventional process control, this movement
can be used for the purpose of diagnostics (RM). In any case, it is required that
monitoring and assessment of RM or PVST is performed by the logic unit of the
safety instrumented system.
Safety function Safe end position feedback:
● Actuator movement can be requested via any input.
● Assessment whether the safety function signals as desired has to be performed
at the end position switches wired directly to the customer connection.
● The actuator is required
- To be either positioned in one of both end positions prior to starting the
test run. The test run is performed out of the end position and back to this
end position.
- Or to be at a sufficient distance from both end positions prior to starting
the test run. The test run is performed into an end position and out of this
end position.
In both cases, the travel distance must sufficient to allow for full tripping of the end
position switch. It must be checked whether the end position switch signals the
expected position both at the beginning, during and at the end of the test.
● Furthermore, test run monitoring must be dynamic. This means a dynamic test
whether the signal change corresponds to the expected value.
Monitoring and assessment of PVST must be ensured by the logic unit of the safety
instrumented system.
Information If PVST is performed out of or into one of both end positions, only the contact of this
end position is checked for correct operation. If both end position switches
(OPEN/CLOSE) are safety relevant, a full stroke test can be performed, for example.
6.4. Maintenance
Maintenance and service tasks may only be performed by authorised personnel who
have been trained on functional safety (refer to chapter 5).
Once maintenance and service tasks have been finished, the functional test must
be completed by a validating process of the safety function including at least the
tests described in the <Safety equipment: check> and <Proof test (verification of
safe actuator function)> chapters.
In case a fault is detected during maintenance, this must be reported to AUMA Riester
GmbH & Co. KG.
Information AUMA actuators prioritise motor operation to manual operation. This means that the
actuator automatically switches to motor operation if requested. However, we recom-
mend activating motor operation after any maintenance and service interventions.
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Multi-turn actuators
Safety-related figures with AM 01.1/AM 02.1/AMExC01.1
7. Safety-related figures
7.1. Determination of the safety-related figures
● The calculation of the safety figures is based on the indicated safety functions.
Hardware assessments are based on Failure Modes, Effects and Diagnostic
Analysis (FMEDA). FMEDA is a step to assess functional device safety in
compliance with IEC 61508. On the basis of FMEDA, the failure rates and the
fraction of safe failures of a device are determined.
● Experience data and data taken from the exida database for mechanical com-
ponents is used to calculate mechanical failure rates. The electronic failure
rates as base failure rates are taken from the SIEMENS Standard SN 29500.
● In compliance with table 2 of IEC 61508-1, the average target PFD values for
systems with low demand mode are:
-2 -1
- SIL 1 safety functions: ≥ 10 to < 10
-3 -2
- SIL 2 safety functions: ≥ 10 to < 10
-4 -3
- SIL 3 safety functions: ≥ 10 to < 10
Since actuators only represent a part of the overall safety function, the actuator
PFD value should not account for more than approx. 25 % of the permissible
total value (PFDavg) of a safety function. This results in the following values:
- Actuator PFD for SIL 1 applications: ≲ 2.50E-02
- Actuator PFD for SIL 2 applications: ≲ 2.50E-03
● Electric actuators with actuator controls are classified as type A components
with a hardware fault tolerance of 0. The SFF for the type A subsystem should
be <60 % according to table 2 of IEC 61508-2 for SIL 1 (subsystems with a
hardware fault tolerance of 0). The SFF for the type A subsystem should be
between 60 % and <90 % according to table 2 of IEC 61508-2 for SIL 2 (sub-
systems with a hardware fault tolerance of 0).
The PFD values specified in the declarations of incorporation and in this safety
manual are only examples and subject to certain assumptions e.g. on Tproof, MTTR,
… The PFD calculation should always be performed individually for each system
using the parameters and conditions applicable for the respective system. The λDU
and λDD values should be used as input. When observing the proof test procedures
indicated in this safety manual, we recommend calculation using proof test coverage
(PTC) of 90 %.4).
As previously mentioned in the architecture section, safeguarding power supply and
resulting calculations are the responsibility of the plant operator.
The plant operator is responsible for eliminating faults within the MTTR, otherwise
the data of the quantitative results is no longer valid.
The safety figures mentioned in this safety manual and in the declarations of
incorporation are only valid if all the conditions stipulated in this safety
manual and in the declarations of incorporation and the mentioned activities
are respected. At the same time, the restrictions regarding the validity and
standard conformity stipulated in the declarations of incorporation must be
heeded.
4) For the example calculations within this manual and the declarations of incorporation, different
PTC values were sometimes used as calculation basis.
14
Multi-turn actuators
with AM 01.1/AM 02.1/AMExC01.1 SIL Declaration of Conformity (example)
15
Multi-turn actuators
SIL Declaration of Conformity (example) with AM 01.1/AM 02.1/AMExC01.1
16
Multi-turn actuators
with AM 01.1/AM 02.1/AMExC01.1 SIL Declaration of Conformity (example)
17
Multi-turn actuators
Index with AM 01.1/AM 02.1/AMExC01.1
S
Index Safe failure fraction (SFF) 3
Safety function 3
A Safety functions 9
Actuator sizing 6 Safety instrumented function 3
Ambient conditions 8 (SIF)
Architecture 6 Safety instrumented system 3
B (SIS)
Brake 6 Safety-related system 3
Self-locking 6
C Service conditions 8
Commissioning 10 Setting 6
Configuration 6 SFF 3
SIL 3
D Standards 5
DC 3
Declaration of Conformity 15 T
Decommissioning 11 Tests 12
Device types 5 T proof 3
Diagnostic coverage (DC) 3
Diagnostics 13
F
Figures, safety-related 14
H
HFT 3
I
Installation 10
Interval for proof test 3
L
Lambda values 3
Lifetime 10
Low Demand Mode 14
M
Maintenance 13
Mean Time Between Failures 3
(MTBF)
MTBF 3
MTTR (Mean Time To Restor- 4
ation)
O
Operation 10
Operation mode 7
P
Partial Valve Stroke Test 13
(PVST)
PFD 3
PFD for actuator 14
Power supply 6
Probability of failure 3, 10
Proof test 4, 12, 12
R
Range of application 5
Reaction Monitoring (RM) 13
18
19
AUMA Riester GmbH & Co. KG
P.O. Box 1362
DE 79373 Muellheim
Tel +49 7631 809 - 0
Fax +49 7631 809 - 1250
[email protected]
www.auma.com
Y006.653/003/en/1.21