Pepperl+Fuchs KFD2-SH-Ex1 Bedienungsanleitung

PL d

Functional Safety

Switch Amplifier

KFD2-SH-Ex1(.T)(.OP),

KHA6-SH-Ex1

PROCESS AUTOMATION

ORIGINAL INSTRUCTIONS

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 KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Content

2017-04

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

1.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

1.3 Symbols Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

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

2.2 Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

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

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

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

3.2 Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

3.4 Characteristic Safety Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.5 Useful Life Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.1 Proof Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6 List of evaluated Sensors . . . . . . . . . . . . . . . . . . . . . . . . 22

7 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 23

8 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Functional Safety Manual HiD2872, HiC2873(Y1), HiD2876, HiC2877

2017-04

Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Introduction

1Introduction

1.1 Contents

This document contains safety-relevant information for usage of the device.

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:

•Presentdocument

• Instruction manual

•Manual

• Datasheet

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

• EU-type of examination

• EU declaration of conformity

• Attestation of conformity

• Certificates

• Control drawings

• FMEDA report

• Assessment report

• Additional documents

For more information about functional safety products from Pepperl+Fuchs see

www.pepperl-fuchs.com/sil.

Note!

For full information on the product, refer to the further documentation on the

Internet at www.pepperl-fuchs.com.

Functional Safety KFD2-SR3-(Ex)2.2S

Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Introduction

2017-04

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.

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.

2017-04

Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Introduction

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 KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Product Description

2017-04

2 Product Description

2.1 Function

General

The devices are safety components according to the machinery directive

2006/42/EC.

This isolated barrier is used for intrinsic safety applications.

The device transfers digital signals (SN/S1N proximity sensors or approved dry

contacts) from a hazardous area to a safe area.

Unlike an SN/S1N series proximity sensor, a mechanical contact requires a

10 kresistor to be placed across the contact in addition to a 1.5 kresistor in

series.

Lead breakage (LB) and short circuit (SC) conditions of the control circuit are

continuously monitored.

During an fault condition, the fault indication output energizes and outputs I and II

de-energize.

For safety applications up to SIL 3, output I must be used. For safety applications

up to SIL 2, output I and output II can be used.

The device is designed for mounting on a 35 mm DIN mounting rail according to

EN 60715.

KFD2-SH-Ex1, KHA6-SH-Ex1

The input controls 1 relay contact output with 3 NO contacts (1 output is in series

to the both output relays for the safety function), 1 relay contact output with

1 NO contact, and 1 passive transistor output (fault indication output).

KFD2-SH-Ex1.T

The input controls 1 active voltage output and 1 relay contact output with a

NO contact.

KFD2-SH-Ex1.T.OP

The input controls 1 active voltage output and 1 relay contact output with a

NO contact.

The device can only be supplied by Power Rail.

Original InstructionsFunctional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

2017-04

Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Product Description

2.2 Interfaces

The device has the following interfaces.

• Safety relevant interfaces: input, output I, output II

• Non-safety relevant interfaces: fault indication output, power supply

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

KFD2-SH-Ex1, KFD2-SH-Ex1.T, KFD2-SH-Ex1.T.OP,

KHA6-SH-Ex1

Up to SIL 3

Up to PL d

Functional safety IEC/EN 61508, part 1 –2, edition 2010:

Functional safety of

electrical/electronic/programmable electronic

safety-related systems (manufacturer)

Machinery Directive 2006/42/EC • EN/ISO 13849, part 1, edition 2015:

Safety-related parts of control systems

(manufacturer)

• IEC/EN 62061,

edition 2005 + A1:2012/2013 + A2:2015:

Safety of machinery –Functional safety of safety-

related electrical, electronic and programmable

electronic control systems

Functional safety IEC/EN 61511, part 1, edition 2003:

Functional safety –Safety instrumented systems for

the process industry sector (user)

Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Planning

2017-04

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)

•theHFTarchitecture(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:

• the PFH value (Probability of dangerous Failure per Hour)

• Fault reaction time of the safety system

• the SFF value (Safe Failure Fraction)

•theHFTarchitecture(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.

Original InstructionsFunctional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

2017-04

Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Planning

3.2 Assumptions

The following assumptions have been made during the FMEDA:

• The fault indication output which signals if the field circuits are broken or

shorted is not considered in the FMEDA and the calculations.

• For output I of the KFD2-SH-Ex1 and KHA6-SH-Ex1 devices, use the

3 redundant relay contacts to establish the necessary redundancy.

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

fault tolerance of 0.

• Observe for the high demand mode the useful lifetime limitations of the output

relays.

• 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/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.

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.

SIL 3 application

If you use output I of the device, you can reach SIL 3 according to IEC 61508.

• The device shall claim less than 10 % of the total failure rate for a SIL 3 safety

loop.

• For a SIL 3 application operating in low demand mode the total PFDavg value

of the SIF (Safety Instrumented Function) should be smaller than 10-3, hence

the maximum allowable PFDavg value would then be 10-4.

• For a SIL 3 application operating in high demand mode the total PFH value of

the SIF should be smaller than 10-7 per hour, hence the maximum allowable

PFH value would then be 10-8 per hour.

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

device, the SFF must be > 90 % according to table 2 of IEC/EN 61508-2 for a

SIL 3 (sub) system.

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