Reference Manual · Publication 1756-RM012 · Rockwell Automation
GuardLogix 5580 & Compact GuardLogix 5380 Safety Reference Manual
This reference manual covers safety application development, operation, and maintenance for GuardLogix 5580 (Bulletin 1756) and Compact GuardLogix 5380 (Bulletin 5069) controllers. It addresses SIL 2 and SIL 3 requirements under IEC 61508, IEC 62061, IEC 61511, and ISO 13849-1, including safety signatures, CIP Safety networking, safety I/O configuration, and system reaction time calculations. TUV Rheinland has approved both controller families for safety-related applications where the de-energized state is the safe state.
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Specifications
Safety Ratings by Controller Configuration
| GuardLogix 5580 primary controller only | SIL 2 / SIL CL 2 / PLd (Cat. 3) per IEC 61508, IEC 62061, IEC 61511, ISO 13849-1 |
|---|---|
| GuardLogix 5580 primary controller with safety partner | SIL 3 / SIL CL 3 / PLe (Cat. 4) per IEC 61508, IEC 62061, IEC 61511, ISO 13849-1 |
| Compact GuardLogix 5380 (cat. no. ends in S2) | SIL 2 / SIL CL 2 / PLd (Cat. 3) |
| Compact GuardLogix 5380 (cat. no. ends in S3) | SIL 3 / SIL CL 3 / PLe (Cat. 4) |
| Approving body | TUV Rheinland |
| Safe state | De-energized state |
Safety Parameters: GuardLogix 5580 with Safety Partner (1oo2, SIL 3)
| Hardware Fault Tolerance (HFT) | 1 |
|---|---|
| Dangerous Undetected Failure Rate (λDU) | 7.38E-11 failures/hr |
| PFDave (Mission Time 20 yr) | 6.46E-06 |
| PFH | 7.38E-11 |
| MTTFd | 160.82 yr |
| Systematic Capability (SC) | 3 |
| Useful Life | 20 years |
Safety Parameters: GuardLogix 5580 Primary Controller Only (1oo1, SIL 2)
| Hardware Fault Tolerance (HFT) | 0 |
|---|---|
| Dangerous Undetected Failure Rate (λDU) | 6.40E-09 failures/hr |
| PFDave (Mission Time 20 yr) | 5.61E-04 |
| PFH | 6.40E-09 |
| MTTFd | 172.74 yr |
| Systematic Capability (SC) | 3 |
Safety Parameters: Compact GuardLogix 5380 SIL 2
| Hardware Fault Tolerance (HFT) | 0 |
|---|---|
| Dangerous Undetected Failure Rate (λDU) | 7.23E-09 failures/hr |
| PFDave (Mission Time 20 yr) | 6.33E-04 |
| PFH | 7.23E-09 |
| MTTFd | 155.66 yr |
Safety Parameters: Compact GuardLogix 5380 SIL 3
| Hardware Fault Tolerance (HFT) | 1 |
|---|---|
| Dangerous Undetected Failure Rate (λDU) | 6.45E-11 failures/hr |
| PFDave (Mission Time 20 yr) | 6.26E-06 |
| PFH | 6.45E-11 |
| MTTFd | 186.08 yr |
Safety Task Parameters
| Period | 2…500 ms |
|---|---|
| Watchdog | 2…500 ms |
| Programming language | Ladder diagram only |
EtherNet/IP Communication
| Onboard Ethernet speed | 10/100/1000 Mbps |
|---|---|
| Minimum firmware of a remote GuardLogix consuming 5580/5380 data | Revision 28 (or use a separate EtherNet/IP module bridging the backplane) |
Catalog Number Format
How to read an Allen-Bradley 1756 catalog number. Each position encodes a specific configuration attribute.
Position
Meaning
Example
Compact GuardLogix 5380 safety rating suffix
Catalog number ending in S2 = SIL 2 / PLd (Cat. 3); ending in S3 = SIL 3 / PLe (Cat. 4)
5069-L320ERS2, 5069-L320ERMS3
Communication Protocols
Supported industrial networks and field buses for the products covered by this publication.
EtherNet/IP (CIP Safety) Onboard port supports 10/100/1000 Mbps. Peer-to-peer safety communication between GuardLogix controllers and safety I/O devices. Black channel communication through non-certified bridges, switches, and routers is supported via the CIP Safety end-node protocol.
DeviceNet (CIP Safety) GuardLogix 5580 uses a ControlLogix DeviceNet bridge module. Compact GuardLogix 5380 accesses DeviceNet safety devices via a 1788-EN2DNR EtherNet/IP-to-DeviceNet linking device.
Backplane (CIP Safety) Peer-to-peer safety communication between two GuardLogix 5580 controllers in the same chassis is supported via the 1756 backplane.
Certifications & Compliance
TUV Rheinland: type-approved and certified for safety applications up to SIL 3 (IEC 61508), SIL CL 3 (IEC 62061), SIL 3 (IEC 61511), PLe Cat. 4 (ISO 13849-1)
Declarations of conformity available at rok.auto/certifications
Document Contents
Full PDF covers the following topics in detail:
- GuardLogix Safety Concept: SIL/PL ratings table, GuardLogix architecture diagrams, safety application requirements, controller useful life, and safety data (PFD, PFH, MTTFd, λDU tables)
- Safety Signature: signature hierarchy, viewing signature elements, signature states (blue/black/gray), archiving reports for audit, signature authentication, and programmatic changes
- GuardLogix and Compact GuardLogix Controller Systems: hardware catalog numbers, primary controller and safety partner roles, chassis and power supply considerations, EtherNet/IP and DeviceNet communication, HMI considerations
- Safety I/O: SIL 2 and SIL 3 wiring considerations, ownership, input/output point operation types, safety I/O configuration signature, device replacement procedures, electronic keying settings, automatic configuration options
- CIP Safety Systems and Safety Network Numbers: SNNs, routable CIP Safety system topology, SNN assignment (time-based and manual formats), UNID concept
- Safety Programming Considerations: safety task parameters, safety programs and routines, safety tags, tag mapping (standard-to-safety), custom tag initialization during prescan, programming restrictions
- Safety Add-On Instructions: instruction signatures, qualification tests, export/import, qualification and verification
- Safety Applications: application development and testing, commissioning lifecycle (specification, project creation, signature generation, validation, confirmation, locking, access restriction), download/upload, memory card, force data, inhibit device, online edits
- Monitor Safety Status and Handle Faults: system status, safety fault types, fault routines, GSV/SSV instructions, safety partner faults
- Safety Application Instructions: safety instructions list, Metal Form instructions, Ladder Diagram safety instructions, Drive Safety instructions
- Safety Reaction Times: connection reaction time limit, system reaction time, Logix system reaction time, factors affecting reaction time, configuring input module delay time, configuring RPI limits, configuring safety task period and watchdog, produced/consumed tag data timing
- Checklists for Safety Applications: controller system checklist, safety inputs checklist, safety outputs checklist, safety application program development checklist
- History of Changes: revision-by-revision change log from 1756-RM012C through 1756-RM012J
Frequently Asked Questions
What SIL and Performance Level ratings do GuardLogix 5580 controllers support?
A GuardLogix 5580 primary controller used alone is rated up to SIL 2 / SIL CL 2 / PLd (Cat. 3) under IEC 61508, IEC 62061, IEC 61511, and ISO 13849-1. When a safety partner (1756-L8SP, 1756-L8SPK, 1756-L8XTSP, or 1756-L8SPXT) is installed in the slot immediately to the right of the primary controller, the system is rated up to SIL 3 / SIL CL 3 / PLe (Cat. 4).
What is the purpose of the safety signature and when is it required?
The safety signature verifies the integrity of the entire safety portion of a controller project. It is a mandatory part of the safety-application development process. The safety signature must be present for the controller to operate at a SIL 2/PLd or SIL 3/PLe rating. Operating without a safety signature is only suitable during development. The signature includes a unique 64-character alphanumeric ID. With firmware revision 38 or later the signature can be generated with the controller in Remote Run, Program/Remote Program, or Remote Test mode; with revision 37 or earlier it must be in Program/Remote Program mode.
What are the hardware fault tolerance (HFT) values for each controller configuration?
The GuardLogix 5580 controller with safety partner (1oo2 architecture) has an HFT of 1. The GuardLogix 5580 primary controller alone has an HFT of 0. The Compact GuardLogix 5380 SIL 2 controller has an HFT of 0, and the Compact GuardLogix 5380 SIL 3 controller has an HFT of 1.
What programming language is supported in the safety task?
Only ladder diagram is supported in the safety task. Standard routines cannot be executed from within the safety task. There can be only one safety task per controller, and it must be configured as a periodic task with a period and watchdog each set between 2 and 500 ms.
How does safety I/O device replacement work when a safety signature exists?
When the controller has a safety signature and the setting is Only Allow Automatic Configuration When No Safety Signature Exists, the controller automatically configures a replacement device only if the device already has the correct safety network number, correct electronic keying, and the correct node or IP address. If the SNN must be set manually, the user must go online, open Module Properties, browse to the safety network number, and click Set to write the SNN to the module, then confirm to accept the replacement. Follow company-prescribed procedures to functionally test the replacement device and system.
How are Safety Network Numbers (SNNs) assigned in a CIP Safety system?
When you create a controller project, the Studio 5000 Logix Designer application automatically generates an SNN whenever a new subnet contains CIP Safety devices. If multiple controllers share safety I/O, the CIP Safety system designer must coordinate SNN values across projects. SNNs can also be assigned manually as 6-byte hexadecimal numbers with a decimal value from 1 to 9999.
What proof test interval is required for GuardLogix controllers within their useful life?
IEC 61508 requires proof tests for equipment used in safety systems, but the GuardLogix controllers have a useful life of 20 years and no proof test is required within that period. The safety calculations in this manual assume component failure rates are constant over the product life and that all detected failures result in the safe state (MRT = 0).
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