Pepperl+Fuchs SIL KFD0-SD2-*. Series Benutzerhandbuch

ISO9001

SOLENOID DRIVER

KFD0-SD2-(Ex)*.*****,

KCD0-SD-(Ex)1.****(.SP),

HiC2871

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 K*D0-SD*-(EX)*.****(.SP), HIC2871

Contents

221278 2012-02

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

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

1.2 Intended Use ................................................................................................5

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 ..................................................................................6

2.1.2 High Demand Mode .................................................................................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 ..................................................................11

4 Proof Test .......................................................................... 12

4.1 Proof Test Procedure ..................................................................................12

4.1.1 Proof Test Procedure KFD0-SD2-(Ex)*.*****...........................................13

4.1.2 Proof Test Procedure KCD0-SD-(Ex)1.****(.SP) .....................................14

4.1.3 Proof Test Procedure HiC2871...............................................................15

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

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SAFETY MANUAL SIL K*D0-SD*-(EX)*.****(.SP), HIC2871

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 it is not possible to correct faults, the devices must be taken out of service

and action taken to protect against accidental use. Devices should 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.

SAFETY MANUAL SIL K*D0-SD*-(EX)*.****(.SP), HIC2871

Introduction

221278 2012-02

1.2 Intended Use

The devices are available as safe area version (KFD0-SD2-*.*****,

KCD0-SD-1.****(.SP)) where they can be used as a signal conditioner providing

isolation for non-intrinsically safe applications. The devices are also available as

hazardous area version (KFD0-SD2-(Ex)*.*****, KCD0-SD-(Ex)1.****(.SP),

HiC2871) allowing use as isolated barriers for intrinsic safety applications.

The safe area versions supply power to solenoids, LEDs, and audible alarms

located in a safe area. The hazardous area versions supply power to solenoids,

LEDs, and audible alarms located in a hazardous area.

The devices are loop powered, so the available energy at the output is received

from the input signal. The output signal has a resistive characteristic. As a result

the output voltage and current are dependent on the load and the input voltage.

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 KFD0-SD2-(Ex)*.***** and KCD0-SD-(Ex)1.****(.SP) are single devices with

DIN rail mounting while the HiC2871 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 SIL3

The stars replace a combination of characters, depending on the product.

1.4 Relevant Standards and Directives

Device specific standards and directives

Functional safety IEC 61508 part 1 –7, 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 –3, edition 2003:

Standard of functional safety: safety instrumented systems for the process

industry sector (user)

KFD0-SD2-(Ex)*.*****

KCD0-SD-(Ex)1.****(.SP)

HiC2871

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SAFETY MANUAL SIL K*D0-SD*-(EX)*.****(.SP), HIC2871

Planning

2 Planning

2.1 System Structure

2.1.1 Low Demand Mode

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

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

the SFF value (Safe Failure Fraction)

the HFT architecture (Hardware Fault Tolerance architecture)

2.1.2 High Demand Mode

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:

PFH (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 = (λs+ λdd) / (λs+ λdd + λdu)

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 K*D0-SD*-(EX)*.****(.SP), HIC2871

Planning

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2.2 Assumptions

The following assumptions have been made during the FMEDA analysis:

Failure rate based on the Siemens SN29500 data base.

The stress levels are average for an industrial environment and can be

compared to the Ground Fixed Classification of MIL-HNBK-217F.

Alternatively, the assumed environment is similar to:

• IEC 60654-1 Class C (sheltered location) with temperature limits within

the manufacturer's rating and an average temperature over a long period

of time of 40 ºC. Humidity levels are assumed within manufacturer's

rating. For a higher average temperature of 60 ºC, the failure rates should

be multiplied with an experience based factor of 2.5. A similar multiplier

should be used if frequent temperature fluctuation must be assumed.

It was assumed that the appearance of a safe error (e. g. output in safe state)

would be repaired within 8 hours (e. g. remove sensor burnout).

During the absence of the device for repairing, measures have to be taken to

ensure the safety function (for example: substitution by an equivalent device).

The HART protocol is only used for setup, calibration, and diagnostic

purposes, not during normal operation.

SIL3 application (loop powered)

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 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 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.

Since the circuit 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

SIL3 (sub)system.

SIL2 application (bus powered)

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.

Since the circuit 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

SIL2 (sub)system.

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SAFETY MANUAL SIL K*D0-SD*-(EX)*.****(.SP), HIC2871

Planning

2.3 Safety Function and Safe State

Safety Function

The output is de-energized if the input is in low condition.

Safe State

The safety function is defined as the output is low/de-energized

(safe state: 0 V, 0 mA).

Reaction Time

The reaction time (switch off delay) for all safety functions is

< 100 ms at Iout > 10 mA.

SAFETY MANUAL SIL K*D0-SD*-(EX)*.****(.SP), HIC2871

Planning

221278 2012-02

2.4 Characteristic Safety Values

The characteristic safety values like PFD, PFH, 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).

Parameters acc. to IEC 61508 Variables

Assessment type and documentation Full assessment

Pepperl+Fuchs FMEDA report 1P+F 05/07-10a R030

Device type A

Demand mode Low Demand Mode or High Demand Mode

Safety function De-energized if the input is in low condition

HFT 0

SIL (hardware) 3

λsd + λsu 114 FIT

λdd 0 FIT

λdu 0 FIT

λtotal (safety function) 227 FIT

SFF 100 %

MTBF 2451 years

PFH 30 1/h

PFDavg for T1= 1 year 30

Tproof max. 3Defined in Proof Test chapter but not necessary to

validate the safety values. See chapter 4.1.

Reaction time < 100 ms

1Pepperl+Fuchs documentation number

2acc. to SN29500. This value includes failures which are not part of the safety function/MTTR = 24 h.

3As the λdfailure rate is 0 FIT, a PFD calculation yields a PFD of zero, independent from the proof test

interval.

Ta b l e 2 . 1

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SAFETY MANUAL SIL K*D0-SD*-(EX)*.****(.SP), HIC2871

Safety Recommendation

3 Safety Recommendation

3.1 Interfaces

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

sheet.

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

Non-safety relevant interfaces: none

3.2 Configuration

A configuration of the device is not necessary and not possible.

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.

Our experience has shown that the useful life time of a Pepperl+Fuchs product

can be higher

if there are no components with reduced life time in the safety path (like

electrolytic capacitors, relays, flash memory, opto coupler) which can produce

dangerous undetected failures and

if the ambient temperature is significantly below 60 °C.

Please note that the useful life time refers to the (constant) failure rate of the

device. The effective life time can be higher.

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