Pepperl+Fuchs KCD2-SON-Ex Series Bedienungsanleitung

ISO9001

Functional Safety

Switch Amplifier

KCD2-SON-Ex*(.R*)(.SP)

PROCESS AUTOMATION

MANUAL

With regard to the supply of products, the current issue of the following document is applicable: The General Terms of

Delivery for Products and Services of the Electrical Industry, published by the Central Association of the Electrical

Industry (Zentralverband Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the

supplementary clause: "Expanded reservation of proprietorship"

Functional Safety KCD2-SON-Ex*(.R*)(.SP)

Content

2018-06

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Content of this Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 Symbols Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.4 Standards and Directives for Functional Safety . . . . . . . . . . . . . . . . . . 8

3 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 System Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Safety Function and Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.4 Characteristic Safety Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.5 Useful Lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.1 Proof Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2018-06

Functional Safety KCD2-SON-Ex*(.R*)(.SP)

Introduction

1Introduction

1.1 Content of this Document

This document contains information for usage of the device in functional safety-related

applications. You need this information to use your product throughout the applicable

stages of the product life cycle. These can include the following:

• Product identification

• Delivery, transport, and storage

• Mounting and installation

• Commissioning and operation

• Maintenance and repair

• Troubleshooting

• Dismounting

• Disposal

The documentation consists of the following parts:

• Present document

• Instruction manual

•Manual

•Datasheet

Additionally, the following parts may belong to the documentation, if applicable:

• EU-type examination certificate

• EU declaration of conformity

• Attestation of conformity

• Certificates

• Control drawings

• FMEDA report

• Assessment report

• Additional documents

For more information about Pepperl+Fuchs products with functional safety,

see www.pepperl-fuchs.com/sil.

Note!

This document does not substitute the instruction manual.

Note!

For full information on the product, refer to the instruction manual and further documentation

on the Internet at www.pepperl-fuchs.com.

Functional Safety KCD2-SON-Ex*(.R*)(.SP)

Introduction

2018-06

1.2 Safety Information

Target Group, Personnel

Responsibility for planning, assembly, commissioning, operation, maintenance,

and dismounting lies with the plant operator.

Only appropriately trained and qualified personnel may carry out mounting, installation,

commissioning, operation, maintenance, and dismounting of the product.

The personnel must have read and understood the instruction manual and the further

documentation.

Intended Use

The device is only approved for appropriate and intended use. Ignoring these instructions

will void any warranty and absolve the manufacturer from any liability.

The device is developed, manufactured and tested according to the relevant safety standards.

Use the device only

• for the application described

• with specified environmental conditions

• with devices that are suitable for this safety application

Improper Use

Protection of the personnel and the plant is not ensured if the device is not used

according to its intended use.

2018-06

Functional Safety KCD2-SON-Ex*(.R*)(.SP)

Introduction

1.3 Symbols Used

This document contains symbols for the identification of warning messages and of

informative messages.

Warning Messages

You will find warning messages, whenever dangers may arise from your actions.

It is mandatory that you observe these warning messages for your personal safety and in order

to avoid property damage.

Depending on the risk level, the warning messages are displayed in descending order

as follows:

Informative Symbols

Action

This symbol indicates a paragraph with instructions. You are prompted to perform an action

or a sequence of actions.

Danger!

This symbol indicates an imminent danger.

Non-observance will result in personal injury or death.

Warning!

This symbol indicates a possible fault or danger.

Non-observance may cause personal injury or serious property damage.

Caution!

This symbol indicates a possible fault.

Non-observance could interrupt the device and any connected systems and plants,

or result in their complete failure.

Note!

This symbol brings important information to your attention.

Functional Safety KCD2-SON-Ex*(.R*)(.SP)

Product Description

2018-06

2 Product Description

2.1 Function

General

This devices are used for intrinsic safety applications.

The devices transfer digital signals (NAMUR sensors or dry contacts) from the hazardous area

to the non-hazardous area.

The devices offer line fault transparency on the signal lines.

A fault is signalized by LEDs and a separate collective error message output.

Via switches the mode of operation can be reversed and the line fault detection

can be switched off.

The devices are available with screw terminals or spring terminals. The type code of

the versions of the devices with spring terminals has the extension ".SP".

The devices are mounted on a 35 mm DIN mounting rail according to EN 60715.

KCD2-SON-Ex1(.SP)

The input controls two passive transistor outputs with a resistive output characteristic

(acc. to EN60947-5-6).

The outputs have three defined states: 1-signal = 1.8 k, 0-signal = 14 kand fault > 100 k.

KCD2-SON-Ex1.R1

The input controls two passive transistor outputs with a resistive output characteristic.

The outputs have three defined states: 1-signal = 6.5 V voltage drop, 0-signal = 33 kand

6.5 V voltage drop and fault > 100 k.

KCD2-SON-Ex1.R2

The input controls two passive transistor outputs with a resistive output characteristic.

The outputs have three defined states: 1-signal = 5 k, 0-signal = 15 kand fault > 100 k.

KCD2-SON-Ex1.R3

The input controls two passive transistor outputs with a resistive output characteristic.

The outputs have three defined states: 1-signal = 100 ... 600 , 0-signal = 19 kand

fault > 100 k.

KCD2-SON-Ex2(.SP)

Each input controls a passive transistor output with a resistive output characteristic

(acc. to EN60947-5-6).

The outputs have three defined states: 1-signal = 1.8 k, 0-signal = 14 kand fault > 100 k.

2018-06

Functional Safety KCD2-SON-Ex*(.R*)(.SP)

Product Description

KCD2-SON-Ex2.R1

Each input controls a passive transistor output with a resistive output characteristic.

The outputs have three defined states: 1-signal = 6.5 V voltage drop, 0-signal = 33 kand

6.5 V voltage drop and fault > 100 k.

KCD2-SON-Ex2.R2

Each input controls a passive transistor output with a resistive output characteristic.

The outputs have three defined states: 1-signal = 5 k, 0-signal = 15 kand fault > 100 k.

KCD2-SON-Ex2.R3

Each input controls a passive transistor output with a resistive output characteristic.

The outputs have three defined states: 1-signal = 100 ... 600 , 0-signal = 19 kand

fault > 100 k.

2.2 Interfaces

The device has the following interfaces.

• Safety-relevant interfaces:

KCD2-SON-Ex1(.R*)(.SP): input I, output I, output II (optional)

KCD2-SON-Ex2(.R*)(.SP): input I, input II, output I, output II

• Non-safety-relevant interfaces: fault output

2.3 Marking

2.4 Standards and Directives for Functional Safety

Device specific standards and directives

System-specific standards and directives

Note!

For corresponding connections see datasheet.

Pepperl+Fuchs GmbH

Lilienthalstraße 200, 68307 Mannheim, Germany

Internet: www.pepperl-fuchs.com

KCD2-SON-Ex1, KCD2-SON-Ex1.SP, KCD2-SON-Ex1.R1,

KCD2-SON-Ex1.R2, KCD2-SON-Ex1.R3,

KCD2-SON-Ex2, KCD2-SON-Ex2.SP, KCD2-SON-Ex2.R1,

KCD2-SON-Ex2.R2, KCD2-SON-Ex2.R3

Up to SIL 2

Functional safety IEC/EN 61508, part 1 –7, edition 2010:

Functional safety of electrical/electronic/programmable

electronic safety-related systems (manufacturer)

Functional safety IEC/EN 61511, part 1 –3, edition 2016:

Functional safety –Safety instrumented systems for the

process industry sector (user)

Functional Safety KCD2-SON-Ex*(.R*)(.SP)

Planning

2018-06

3 Planning

3.1 System Structure

3.1.1 Low Demand Mode of Operation

If there are two control loops, one for the standard operation and another one for the

functional safety, then usually the demand rate for the safety loop is assumed to be less

than once per year.

The relevant safety parameters to be verified are:

•thePFD

avg value (average Probability of dangerous Failure on Demand) and the

T1value (proof test interval that has a direct impact on the PFDavg value)

• the SFF value (Safe Failure Fraction)

• the HFT architecture (Hardware Fault Tolerance)

3.1.2 High Demand or Continuous Mode of Operation

If there is only one safety loop, which combines the standard operation and safety-related

operation, then usually the demand rate for this safety loop is assumed to be higher

than once per year.

The relevant safety parameters to be verified are:

•thePFHvalue(Probability of dangerous Failure per Hour)

• Fault reaction time of the safety system

• the SFF value (Safe Failure Fraction)

• the HFT architecture (Hardware Fault Tolerance)

3.1.3 Safe Failure Fraction

The safe failure fraction describes the ratio of all safe failures and dangerous detected failures

to the total failure rate.

SFF = (s+ dd) / (s+ dd + du)

A safe failure fraction as defined in IEC/EN 61508 is only relevant for elements or (sub)systems

in a complete safety loop. The device under consideration is always part of a safety loop

but is not regarded as a complete element or subsystem.

For calculating the SIL of a safety loop it is necessary to evaluate the safe failure fraction

of elements, subsystems and the complete system, but not of a single device.

Nevertheless the SFF of the device is given in this document for reference.

2018-06

Functional Safety KCD2-SON-Ex*(.R*)(.SP)

Planning

3.2 Assumptions

The following assumptions have been made during the FMEDA:

• The device shall claim less than 10 % of the total failure budget for a SIL 2 safety loop.

• For a SIL 2 application operating in low demand mode the total PFDavg value of the

SIF (Safety Instrumented Function) should be smaller than 10-2, hence the maximum

allowable PFDavg value would then be 10-3.

• For a SIL 2 application operating in high demand mode the total PFH value of the

SIF should be smaller than 10-6 per hour, hence the maximum allowable PFH value would

then be 10-7 per hour.

• The safety-related device is considered to be of type Adevice with a hardware fault

tolerance of 0.

• Since the safety loop has a hardware fault tolerance of 0and it is a type Adevice,

the SFF must be > 60 % according to table 2 of IEC/EN 61508-2 for a SIL 2 (sub) system.

• Failure rate based on the Siemens standard SN29500.

• Failure rates are constant, wear is not considered.

• External power supply failure rates are not included.

• The stress levels are average for an industrial environment and the environment is similar

to IEC/EN 60654-1 Class C (sheltered location) with temperature limits in the range

of the manufacturer's specifications and an average temperature of 40 ºC over a long

period. The humidity level is within manufacturer's rating.

• The listed failure rates are valid for operating stress conditions typical of an industrial field

environment similar to IEC/EN 60654-1 Class C with an average temperature over a long

period of time of 40 ºC. For a higher average temperature of 60 ºC, the failure rates must

be multiplied by a factor of 2.5 based on experience. A similar factor must be used

if frequent temperature fluctuations are expected.

• Since the outputs of the device use common components, these outputs must not be used

in the same safety function.

• The indication of a dangerous failure (via fault bus) is detected within 1 hour

by the programmable logic controller (PLC).

• The collective error message output is not considered in the FMEDA and

in the calculations.

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