Pepperl+Fuchs SIL KFD0-RSH-1 Benutzerhandbuch

ISO9001

Relay Module

KFD0-RSH-1(-Y2), KFD2-SL-4

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 KFD0-RSH-1(-Y2), KFD2-SL-4

Contents

2014-07

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

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

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

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

3 Safety Recommendation ................................................. 12

3.1 Interfaces ....................................................................................................12

3.2 Configuration ..............................................................................................12

3.3 Useful Life Time ..........................................................................................12

3.4 Installation and Commissioning ..................................................................13

4 Proof Test.......................................................................... 14

4.1 Proof Test Procedure..................................................................................14

5 Abbreviations ................................................................... 17

Safety Manual SIL KFD0-RSH-1(-Y2), KFD2-SL-4

2014-07

Safety Manual SIL KFD0-RSH-1(-Y2), KFD2-SL-4

Introduction

1Introduction

1.1 General Information

This manual contains information on using the device in control circuits that are

related to functional safety.

The corresponding data sheets, the operating instructions, the system

description, the declaration of conformity, the EC-Type Examination Certificate,

and the applicable certificates (see data sheet) are an integral part of this

document.

The stated documents are available at www.pepperl-fuchs.com or from 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.

In the event of a device fault, the devices must be taken out of operation and

measures must be taken to protect them against unintentional startup. Devices

may be repaired only by the manufacturer. Deactivating or bypassing safety

functions, or failing to observe the instructions in this manual (which lead to faults

or affect the safety functions), can damage property and the environment or

cause personal injury, for which Pepperl+Fuchs GmbH accepts no liability.

The devices have been developed, manufactured, and tested according to the

applicable safety standards. The devices may be used only for the applications

described in the instructions under the specified ambient conditions and

exclusively in connection with the approved peripherals.

1.2 Intended Use

General

The devices are single devices for DIN rail mounting.

KFD0-RSH-1(-Y2)

These signal conditioners provides the galvanic isolation between field circuits

and control circuits.

The devices are relay modules that are suitable for safely switching applications

of a load circuit. The devices isolate load circuits up to 230 V and the 24 V control

interface.

The devices can also be used as interfaces in output loops for ESD (Emergency

Shut Down) systems classified as SIL3. The safe state in this application is de-

energized to safe. The output has three relays that are of diverse design, but have

a common effect on the output. An additional fuse in series to the relay contacts is

available.

The KFD0-RSH-1-Y2 is protected against high pulses during OFF state, low

pulses during ON state and a load impedance check.

Safety Manual SIL KFD0-RSH-1(-Y2), KFD2-SL-4

Introduction

2014-07

KFD2-SL-4

The devices are 4-channel signal conditioners with outputs that switch up to

600 mA to high-power solenoids. The devices are also used as power amplifier

up to a switching frequency of 1 kHz.

For functional safety applications, the common disable input is used to switch off

all outputs when de-energized. The devices can be used for applications up to

SIL2

Two channels per module can be paralleled. The output current of a parallel

combination is 1.2 A. If the supply voltage falls below 18 V, the outputs will be

switched off. The outputs are sustained short-circuit proofed and overload-

proofed.

Line fault detection can be enabled via DIP switch. Fault LED and collective error

output via Power Rail behave as described within the data sheet of the device.

1.3 Manufacturer Information

Pepperl+Fuchs GmbH

Lilienthalstrasse 200, 68307 Mannheim, Germany

KFD0-RSH-1, KFD0-RSH-1-Y2

KFD2-SL-4

1.4 Relevant Standards and Directives

Device specific standards and directives



Functional safety IEC 61508 part 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)

Up to SIL3

Up to SIL2

2014-07

Safety Manual SIL KFD0-RSH-1(-Y2), KFD2-SL-4

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 PFD

avg

value (average Probability of Failure on Demand) and the T

proof

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

avg

)



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 = (

+ 

) / (

+ 

)

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 KFD0-RSH-1(-Y2), KFD2-SL-4

Planning

2014-07

2.2 Assumptions

The following assumptions have been made during the FMEDA analysis:



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 PFD

avg

value

of the SIF (Safety Instrumented Function) should be smaller than 10

-2

, hence

the maximum allowable PFD

avg

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.



The device shall claim less than 10 % of the total failure budget for a SIL3

safety loop.



For a SIL3 application operating in Low Demand Mode the total PFD

avg

value

of the SIF (Safety Instrumented Function) should be smaller than 10

-3

, hence

the maximum allowable PFD

avg

value would then be 10

-4



For a SIL3 application operating in High Demand Mode of operation 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.



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.



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

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

SIL3 (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.

2014-07

Safety Manual SIL KFD0-RSH-1(-Y2), KFD2-SL-4

Planning



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).



Since the two outputs of the device use common components, these outputs

must not be used in the same safety function.



For the KFD0-RSH devices, the relay outputs need protection by a fuse

initiating at 80 % of the rated current to avoid contact welding.

2.3 Safety Function and Safe State

Safety Function

KFD0-RSH-1(-Y2): Whenever the input of the device is de-energized, the output

is de-energized.

KFD2-SL-4: Whenever the common disable input is de-energized, all outputs are

de-energized.

Safe State

The safe state is defined as all outputs being de-energized (not conducting)

The KFD2-SL-4 is configurable. The settings do not influence the safety function.

The settings only cause reactions on the additional error output.

Switching Frequency

The maximum switching frequency in the safety relevant input (for KFD2-SL-4 the

common disable input) is 10 Hz.

For the KFD2-SL-4, the maximum switching frequency for the not safety relevant

signal transfer is 1 kHz.

Safety Manual SIL KFD0-RSH-1(-Y2), KFD2-SL-4

Planning

2014-07

2.4 Characteristic Safety Values

KFD0-RSH-1

Parameters acc. to IEC 61508 Values

Assessment type and documentation FMEDA report

Device type A

Mode of operation Low Demand Mode or High Demand Mode

HFT 0

SIL 3

Safety function Output relay in OFF state when input is de-

energized



251.6 FIT



0 FIT



0.4 FIT



no effect

69.6 FIT



total (safety function)

252 FIT

SFF 99.8 %

MTBF

452 years

PFH 4.00 x 10

-10

1/h

PFD

avg

for T

proof

= 1 year 1.75 x 10

-6

PFD

avg

for T

proof

= 2 years 3.50 x 10

-6

PFD

avg

for T

proof

= 5 years 8.76 x 10

-6

Reaction time

< 20 ms

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

Time between fault detection and fault reaction.

Table 2.1

2014-07

Safety Manual SIL KFD0-RSH-1(-Y2), KFD2-SL-4

Planning

KFD0-RSH-1-Y2

Parameters acc. to IEC 61508 Values

Assessment type and documentation FMEDA report

Device type A

Mode of operation Low Demand Mode or High Demand Mode

HFT 0

SIL 3

Safety function Output relay in OFF state when input is de-

energized



255 FIT



0 FIT



4.4 FIT



no effect

72.8 FIT



total (safety function)

259 FIT



not part

0 FIT

SFF 98.3 %

MTBF

440 years

PFH 4.38 x 10

-9

1/h

PFD

avg

for T

proof

= 1 year 1.91 x 10

-5

PFD

avg

for T

proof

= 2 years 3.82 x 10

-5

PFD

avg

for T

proof

= 5 years 9.59 x 10

-5

Reaction time

< 20 ms

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

Time between fault detection and fault reaction.

Table 2.2

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