Pepperl+Fuchs KCD2-SR-1.LB Benutzerhandbuch

ISO9001

Switch Amplifier

KCD2-SR-(Ex)*(.LB)(.SP),

HiC282*

PROCESS AUTOMATION

SAFETY MANUAL SIL

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"

Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

Contents

2014-09

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

1.1 General Information ......................................................................................4

1.2 Intended Use ................................................................................................4

1.3 Manufacturer Information..............................................................................5

1.4 Relevant Standards and Directives...............................................................5

2 Planning .............................................................................. 6

2.1 System Structure ..........................................................................................6

2.1.1 Low Demand Mode of Operation .............................................................6

2.1.2 High Demand or Continuous Mode of Operation......................................6

2.1.3 Safe Failure Fraction ................................................................................6

2.2 Assumptions .................................................................................................7

2.3 Safety Function and Safe State.....................................................................8

2.4 Characteristic Safety Values.........................................................................9

3 Safety Recommendation ................................................. 10

3.1 Interfaces....................................................................................................10

3.2 Configuration ..............................................................................................10

3.3 Useful Life Time ..........................................................................................10

3.4 Installation and Commissioning ..................................................................12

4 Proof Test.......................................................................... 13

4.1 Proof Test Procedure..................................................................................13

5 Abbreviations ................................................................... 16

Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

2014-09

Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

Introduction

1Introduction

1.1 General Information

This manual contains information for application of the device in functional safety

related loops.

The corresponding data sheets, the operating instructions, the system

description, the Declaration of Conformity, the EC-Type-Examination Certificate,

the Functional Safety Assessment and applicable Certificates (see data sheet)

are integral parts of this document.

The documents mentioned are available from www.pepperl-fuchs.com or by

contacting your local Pepperl+Fuchs representative.

Mounting, installation, commissioning, operation, maintenance and disassembly

of any devices may only be carried out by trained, qualified personnel. The

instruction manual must be read and understood.

When a fault is detected within the device, it must be taken out of service and

action taken to protect against accidental use. Devices shall only be repaired

directly by the manufacturer. De-activating or bypassing safety functions or failure

to follow the advice given in this manual (causing disturbances or impairment of

safety functions) may cause damage to property, environment or persons for

which Pepperl+Fuchs GmbH will not be liable.

The devices are developed, manufactured and tested according to the relevant

safety standards. They must only be used for the applications described in the

instructions and with specified environmental conditions, and only in connection

with approved external devices.

1.2 Intended Use

The devices are available as safe area version (KCD2-SR-*(.LB)(.SP)) where

they can be used as a signal conditioner providing isolation for non-intrinsically

safe applications. Also the devices are available as hazardous area version

(KCD2-SR-Ex*(.LB)(.SP), HiC282*) allowing use as isolated barriers for intrinsic

safety applications.

The safe area versions transfer digital signals (NAMUR sensors/mechanical

contacts) via a galvanic isolation. The hazardous area versions transfer these

signals from a hazardous to a safe area.

The proximity sensor or switch controls a normally open relay output for the safe

area load. The device output changes state when the input signal changes state.

The normal output state can be reversed via DIP switches.

In the KCD2-SR-(Ex)1.LB(.SP) versions, output II can be switched to either follow

output I or to detect faults on the input line (line break, short circuit).

Line fault detection (LFD) can be selected or disabled via a DIP switch.

During an error condition the outputs de-energize.

Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

Introduction

2014-09

A fault is signalized by LEDs acc. to NAMUR NE44 and a separate collective error

message output.

The KC devices are available with screw terminals or spring terminals. The type

code of the versions of the KC-devices with spring terminals has the

extension ".SP".

The KCD2-SR-(Ex)*(.LB)(.SP) is a single device for DIN rail mounting while the

HiC282* is a plug-in device to be inserted into a specific Termination Board.

1.3 Manufacturer Information

Pepperl+Fuchs GmbH

Lilienthalstrasse 200, 68307 Mannheim, Germany

Up to SIL2

1.4 Relevant Standards and Directives

Device specific standards and directives

Functional safety IEC 61508 part 1 –2, edition 2000:

Standard of functional safety of electrical/electronic/programmable electronic

safety-related systems (product manufacturer)

Electromagnetic compatibility:

- EN 61326-1:2006

- NE 21:2006

System specific standards and directives

Functional safety IEC 61511 part 1, edition 2003:

Standard of functional safety: safety instrumented systems for the process

industry sector (user)

KCD2-SR-1.LB(.SP)

KCD2-SR-Ex1.LB(.SP)

KCD2-SR-2(.SP)

KCD2-SR-Ex2(.SP)

HiC2821, HiC2822

2014-09

Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

Planning

2 Planning

2.1 System Structure

2.1.1 Low Demand Mode of Operation

If there are two 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:

the PFDavg value (average Probability of Failure on Demand) and the Tproof

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

the SFF value (Safe Failure Fraction)

the HFT architecture (Hardware Fault Tolerance)

2.1.2 High Demand or Continuous Mode of Operation

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

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

higher than once per year.

The relevant safety parameters to be verified are:

the PFH value (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 architecture)

2.1.3 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 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.

Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

Planning

2014-09

2.2 Assumptions

The following assumptions have been made during the FMEDA analysis:

Only one input and one output are part of the considered safety function

(only 2-channel version).

The device shall claim less than 10 % of the total failure budget for a SIL2

safety loop.

For a SIL2 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 SIL2 application operating in High Demand Mode of operation 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.

Failure rate based on the Siemens SN29500 data base.

Failure rates are constant, wear out mechanisms are not included.

External power supply failure rates are not included.

The safety-related device is considered to be of type Acomponents with a

Hardware Fault Tolerance of 0.

Since the loop has a Hardware Fault Tolerance of 0and it is a type A

component, the SFF must be > 60 % according to table 2 of IEC 61508-2 for a

SIL2 (sub)system.

It is assumed that the device will be used under average industrial ambient

conditions, which are comparable with the classification "stationary mounted"

in MIL-HDBK-217F. Alternatively, the following ambient conditions are

assumed:

• IEC 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. A moisture level within the manufacturer's

specifications is assumed. For a higher average temperature of 60 ºC,

the failure rates must be multiplied by a factor of 2.5 based on empirical

values. A similar multiplier must be used if frequent temperature

fluctuations are expected.

It is assumed that any safe failures that occur (e.g., output in safe condition)

will be corrected within eight hours (e.g., correction of a sensor fault).

While the device is being repaired, measures must be taken to maintain the

safety function (e.g., by using a replacement device).

The indication of a dangerous fault (via fault bus) is detected within 1 hour by

the programmable logic controller (PLC).

2014-09

Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

Planning

2.3 Safety Function and Safe State

The safe state of each channel is "output de-energized", independent of the

mode of operation.

The safety function has two modes of operation:

normal operation (output follows input)

inverted operation (output inverts input)

The one channel devices have two outputs where output II may be used in safety

relevant applications if it is configured to follow output I.

Therefore the DIP switch settings for all channels used in safety relevant

applications are:

DIP Switch Settings 1-channel Devices

DIP Switch Settings 2-channel Devices

LB/SC Diagnosis

The input loop of all versions is supervised, if the line fault detection is active

(mandatory, see data sheet). The related output goes to the safe state in case of

line fault.

Function Mode KCD2-SR-(Ex)1.LB(.SP) HiC2821

Output I normal mode normal mode S1 position I S1 position II

inverted mode S1 position II S1 position I

Assignment output II follow output I S2 position I S3 position I

LB/SC detection1S2 position II S3 position II

Line fault detection ON S3 position I S2 position I

OFF2S3 position II S2 position II

1This mode may not be used if output II is used for safety relevant applications.

2This switch setting may not be used if the device is used for safety relevant applications.

Table 2.1

Function Mode KCD2-SR-(Ex)2(.SP) HiC2822

Mode channel 1 normal mode S1 position I S1 position II

inverted mode S1 position II S1 position I

Mode channel 2 normal mode S2 position I S3 position II

inverted mode S2 position II S3 position I

Line fault detection

channel 1

ON S3 position I S2 position I

OFF1S3 position II S2 position II

Line fault detection

channel 2

ON S4 position I S4 position I

OFF1S4 position II S4 position II

1This switch setting may not be used if the channel is used for safety relevant applications.

Table 2.2

Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

Planning

2014-09

Reaction Time

The reaction time for all safety functions is < 20 ms.

2.4 Characteristic Safety Values

The characteristic safety values like PFD, SFF, HFT and Tproof are taken from the

SIL report/FMEDA report. Please note, PFD and Tproof are related to each other.

The function of the devices has to be checked within the proof test interval

(Tproof).

Note!

The failure outputs are not safety relevant.

Parameters acc. to IEC 61508 Values

Assessment type and

documentation

Full assessment

Device type A

Mode of operation Low Demand Mode or High Demand Mode

HFT 0

SIL 2

Safety function One relay output of one channel Two relay outputs of a one

channel device in series

s189 FIT 216 FIT

dd 18 FIT 48 FIT

du 47 FIT 45 FIT

no effect 89 FIT 90 FIT

total (safety function) 254 FIT 309 FIT

not part 58 FIT 58 FIT

SFF 81.55 % 85.4 %

MTBF 1365 years 311 years

PFH 4.68 x 10-8 1/h 4.51 x 10-8 1/h

PFDavg for Tproof = 1 year 2.05 x 10-4 1.97 x 10-4

PFDavg for Tproof = 2 years 4.10 x 10-4 3.95 x 10-4

PFDavg for Tproof = 5 years 1.02 x 10-3 9.86 x 10-4

Reaction time 2< 20 ms

1acc. to SN29500. This value includes failures which are not part of the safety function.

2Time between fault detection and fault reaction.

Table 2.3

2014-09

Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

Safety Recommendation

3 Safety Recommendation

3.1 Interfaces

The device has the following interfaces. For corresponding terminals see data

sheet.

Safety relevant interfaces:

KCD2-SR-(Ex)1.LB(.SP), HiC2821: input I, output I, output II

KCD2-SR-(Ex)2(.SP), HiC2822: input I, input II, output I, output II

Non-safety relevant interfaces: output ERR

3.2 Configuration

The device must be configured through the user accessible DIP switches for the

required output function before the start-up. During the functionality any change

of the operating function (DIP switch modification) can invalidate the safety

function behavior and must be avoided.

The KCD2 devices provide a suitable cover to protect against accidental changes

while on the HiC devices the access to the DIP switch is permitted only through a

small window on the side and by a small screw driver.

3.3 Useful Life Time

Although a constant failure rate is assumed by the probabilistic estimation this

only applies provided that the useful life time of components is not exceeded.

Beyond this useful life time, the result of the probabilistic calculation is

meaningless as the probability of failure significantly increases with time. The

useful life time is highly dependent on the component itself and its operating

conditions –temperature in particular (for example, the electrolytic capacitors can

be very sensitive to the working temperature).

This assumption of a constant failure rate is based on the bathtub curve, which

shows the typical behavior for electronic components.

Therefore it is obvious that failure calculation is only valid for components that

have this constant domain and that the validity of the calculation is limited to the

useful life time of each component.

It is assumed that early failures are detected to a huge percentage during the

installation period and therefore the assumption of a constant failure rate during

the useful life time is valid.

However, according to IEC 61508-2, a useful life time, based on experience,

should be assumed. Experience has shown that the useful life time often lies

within a range period of about 8 ... 12 years.

As noted in DIN EN 61508-2:2011 note NA4, appropriate measures taken by the

manufacturer and operator can extend the useful lifetime.

Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

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