GMI D6038S Series User guide

D6038 - SIL3 Line-Fault Transp. Switch/Prox. Repeater G.M. International ISM0433-0
SIL3 Line-Fault Transp. Switch/Prox. Repeater,
DIN-Rail and Termination Board
Models D6038S*, D6038D*, D6038X*
D6038S*, D6038D*, D6038X*
SAFETY MANUAL
Reference must be made to the relevant sections within the instruction manual ISM0431,
which contain basic guides for the installation of the equipment.

D6038 - SIL3 Line-Fault Transp. Switch/Prox. Repeater G.M. International ISM0433-0
2
Functional Safety Manual and Application
Application for single channel D6038SA or D6038SB
Description:
For this application, enable input line fault (open or short) detection and choose direct or reverse input to output transfer function, by set the internal dip-switches in the following mode
(for more information, please see the instruction manual ISM0431):
D6038SA
or
D6038SB
(Ch.1)
OFF operation ON operation
Field Input: proximity is OFF
or switch is open
Channel 1
D6038SA
or
D6038SB
(Ch.1)
Field Input: proximity is ON
or switch is closed
Channel 1
1
2 Out 1
The module is powered by connecting 24 Vdc power supply to Pins 5 (+ positive) - 6 (- negative). The green LED is lit in presence of supply power.
Input signal from field is applied to Pins 7-8 (In 1 - Ch.1). Output Pins 1-2 (for Channel 1) has got RH (direct function) or RL (reverse function) resistance value for OFF operation, while
it has got RL (direct function) or RH (reverse function) resistance value for ON operation. The following table describes for Channel 1 the output resistance value when its input signal is
in OFF or ON state, and it gives information about turn-on or turn-off of its channel status LED and channel fault LED:
Dip-switch position 1 2 3 4
ON/OFF state ON OFF (direct) or ON (reverse) Not used Not used
7
8
In 1
7
8
In 1
Supply
24 Vdc
5 + 6 -
Supply
24 Vdc
5 + 6 -
Input 1 signal state
Pins 7-8 (In 1 - Ch.1)
Out 1 resistance value
Pins 1-2 (Out 1 - Ch.1)
Channel 1 status
yellow LED state
Channel 1 fault
red LED state
Proximity sensor is OFF or switch is open RH (direct function) or RL (reverse function) OFF (direct function)
ON (reverse function) OFF
Proximity sensor is ON or switch is closed RL (direct function) or RH (reverse function) ON (direct function)
OFF (reverse function) OFF
Independently from proximity sensor or switch state, input line is broken RH (direct or reverse function) as safe state condition OFF (direct or reverse
function) ON
Independently from proximity sensor or switch state, input line is short circuited RH (direct or reverse function) as safe state condition OFF (direct or reverse
function) ON
Safety Function and Failure behavior:
D6038S is considered to be operating in Low Demand mode, as a Type A module, having Hardware Fault Tolerance (HFT) = 0.
The failure behaviour is described from the following definitions :
□fail-Safe State: it is defined as two cases: 1st) the channel output being open, with output resistance equal or bigger than RH ; 2nd) the channel output being in short circuit,
with output resistance equal to zero or very little than RL. The module output must be monitored by a Digital Input channel of a Safety PLC in order to detect open circuit (very
high resistance) or short circuit (very low resistance) of output channel;
□fail Safe: failure mode that causes the module / (sub)system to go to the defined Fail-Safe state without a demand from the process;
□fail Dangerous: failure mode that does not respond to a demand from the process (i.e. being unable to go to the defined Fail-Safe state), so that the channel output is blocked
in closed position, with output resistance equal or less than RL, but not equal to short circuit therefore not detectable by a Digital Input channel of a Safety PLC;
□fail “No Effect”: failure mode of a component that plays a part in implementing the safety function but that is neither a safe failure or a dangerous failure.
When calculating the SFF this failure mode is not taken into account;
□fail “Not part”: failure mode of a component which is not part of the safety function but part of the circuit diagram and is listed for completeness.
When calculating the SFF this failure mode is not taken into account. It is also not considered for the total failure rate (safety function) evaluation.
Failure rate date: taken from Siemens Standard SN29500.
Failure category Failure rates (FIT)
λdd = Total Dangerous Detected failures 0.00
λdu = Total Dangerous Undetected failures 10.40
λsd = Total Safe Detected failures 0.00
λsu = Total Safe Undetected failures 206.10
λtot safe = Total Failure Rate (Safety Function) = λdd + λdu + λsd + λsu 216.50
MTBF (safety function, one channel) = (1 / λtot safe) + MTTR (8 hours) 527 years
λno effect = “No Effect” failures 224.20
λnot part = “Not Part” failures 12.40
λtot device = Total Failure Rate (Device) = λtot safe + λno effect + λnot part 453.10
MTBF (device) = (1 / λtot device) + MTTR (8 hours) 252 years
λsd λsu λdd λdu SFF
0.00 FIT 206.10 FIT 0.00 FIT 10.40 FIT 95.2%
Failure rates table according to IEC 61508:2010 Ed.2 :
Failure rate table:
T[Proof] = 1 year T[Proof] = 2 years
PFDavg = 4.56 E-05 Valid for SIL 3 PFDavg = 9.13 E-05 Valid for SIL 3
PFDavg vs T[Proof] table (assuming Proof Test coverage of 99%), with determination of SIL supposing module contributes >10% of total SIF dangerous failures:
PFDavg vs T[Proof] table (assuming Proof Test coverage of 99%), with determination of SIL supposing module contributes ≤10% of total SIF dangerous failures:
T[Proof] = 5 years
PFDavg = 2.28 E-04 Valid for SIL 3
SC3: Systematic capability SIL 3.
Out 1 resistance value is RL (for
direct function) or RH (for reverse
function)
Out 1 resistance value is RH (for
direct function) or RL (for reverse
function)
Safety
PLC
Input
1
2 Out 1
Safety
PLC
Input

D6038 - SIL3 Line-Fault Transp. Switch/Prox. RepeaterG.M. International ISM0433-0 3
Functional Safety Manual and Application
Application for double channel D6038DA or D6038DB
D6038DA
or
D6038DB
(Ch.1 and Ch.2)
OFF operation ON operation
Field Input: proximity is OFF
or switch is open
Channel 1
D6038DA
or
D6038DB
(Ch.1 and Ch.2)
Field Input: proximity is ON
or switch is closed
Channel 1
1
2 Out 1
7
8
In 1
7
8
In 1
Supply
24 Vdc
5 + 6 -
Supply
24 Vdc
5 + 6 -
Out 1 resistance value is RL (for
direct function) or RH (for reverse
function)
Out 1 resistance value is RH (for
direct function) or RL (for reverse
function)
Safety
PLC
Input
1
2 Out 1
Safety
PLC
Input
Out 2 resistance value is RH (for
direct function) or RL (for reverse
function)
3
4 Out 2
Safety
PLC
Input
9
10
In 2 Channel 2
9
10
In 2 Channel 2
3
4 Out 2
Out 2 resistance value is RL (for
direct function) or RH (for reverse
function)
Safety
PLC
Input
Description:
For this application, for each channel enable input line fault (open or short) detection and choose direct or reverse input to output transfer function, by set the internal dip-switches in the
following mode (for more information, please see the instruction manual ISM0431), where dip 1 and 2 are related to Ch.1 and dip 3 and 4 are related to Ch.2:
Dip-switch position 1 2 3 4
ON/OFF state ON OFF (direct) or ON (reverse) ON OFF (direct) or ON (reverse)
The module is powered by connecting 24 Vdc power supply to Pins 5 (+ positive) - 6 (- negative). The green LED is lit in presence of supply power.
Input signals from field are applied to Pins 7-8 (In 1 - Ch.1) and Pins 9-10 (In 2 - Ch.2). Output Pins 1-2 (for Channel 1) and Output Pins 3-4 (for Channel 2) have got RH (direct
function) or RL (reverse function) resistance value for OFF operation, while they have got RL (direct function) or RH (reverse function) resistance value for ON operation. The following
table describes for each channel (Channel 1 or Channel 2) the output resistance value when its input signal is in OFF or ON state, and it gives information about turn-on or turn-off
of its channel status LED and channel fault LED:
Input 1 or Input 2 signal state
Pins 7-8 (In 1 - Ch.1) or Pins 9-10 (In 2 - Ch.2)
Out 1 or Out 2 resistance value
Pins 1-2 (Out 1 - Ch.1) or Pins 3-4 (Out 2 - Ch.2)
Ch.1 or Ch.2 status
yellow LED state
Ch.1 or Ch.2 fault
red LED state
Proximity sensor is OFF or switch is open RH (direct function) or RL (reverse function) OFF (direct function)
ON (reverse function) OFF
Proximity sensor is ON or switch is closed RL (direct function) or RH (reverse function) ON (direct function)
OFF (reverse function) OFF
Independently from proximity sensor or switch state, input line is broken RH (direct or reverse function) as safe state condition OFF (direct or reverse
function) ON
Independently from proximity sensor or switch state, input line is short circuited RH (direct or reverse function) as safe state condition OFF (direct or reverse
function) ON
Safety Function and Failure behavior:
D6038D is considered to be operating in Low Demand mode, as a Type A module, having Hardware Fault Tolerance (HFT) = 0.
For each channel, the failure behaviour is described from the following definitions :
□fail-Safe State: it is defined as two cases: 1st) the channel output being open, with output resistance equal or bigger than RH ; 2nd) the channel output being in short circuit,
with output resistance equal to zero or very little than RL. The module output must be monitored by a Digital Input channel of a Safety PLC in order to detect open circuit (very
high resistance) or short circuit (very low resistance) of output channel;
□fail Safe: failure mode that causes the module / (sub)system to go to the defined Fail-Safe state without a demand from the process;
□fail Dangerous: failure mode that does not respond to a demand from the process (i.e. being unable to go to the defined Fail-Safe state), so that the channel output is blocked
in closed position, with output resistance equal or less than RL, but not equal to short circuit therefore not detectable by a Digital Input channel of a Safety PLC;
□fail “No Effect”: failure mode of a component that plays a part in implementing the safety function but that is neither a safe failure or a dangerous failure.
When calculating the SFF this failure mode is not taken into account;
□fail “Not part”: failure mode of a component which is not part of the safety function but part of the circuit diagram and is listed for completeness.
When calculating the SFF this failure mode is not taken into account. It is also not considered for the total failure rate (safety function) evaluation.
Failure rate date: taken from Siemens Standard SN29500.
Failure category Failure rates (FIT)
λdd = Total Dangerous Detected failures 0.00
λdu = Total Dangerous Undetected failures 10.40
λsd = Total Safe Detected failures 0.00
λsu = Total Safe Undetected failures 211.70
λtot safe = Total Failure Rate (Safety Function) = λdd + λdu + λsd + λsu 222.10
MTBF (safety function, one channel) = (1 / λtot safe) + MTTR (8 hours) 514 years
λno effect = “No Effect” failures 244.90
λnot part = “Not Part” failures 337.70
λtot device = Total Failure Rate (Device) = λtot safe + λno effect + λnot part 804.70
MTBF (device) = (1 / λtot device) + MTTR (8 hours) 142 years
λsd λsu λdd λdu SFF
0.00 FIT 211.70 FIT 0.00 FIT 10.40 FIT 95.3%
Failure rates table according to IEC 61508:2010 Ed.2 :
Failure rate table:
T[Proof] = 1 year T[Proof] = 2 years
PFDavg = 4.56 E-05 Valid for SIL 3 PFDavg = 9.13 E-05 Valid for SIL 3
PFDavg vs T[Proof] table (assuming Proof Test coverage of 99%), with determination of SIL supposing module contributes >10% of total SIF dangerous failures:
PFDavg vs T[Proof] table (assuming Proof Test coverage of 99%), with determination of SIL supposing module contributes ≤10% of total SIF dangerous failures:
T[Proof] = 5 years
PFDavg = 2.28 E-04 Valid for SIL 3
SC3: Systematic capability SIL 3.

D6038 - SIL3 Line-Fault Transp. Switch/Prox. Repeater G.M. International ISM0433-0
4
Functional Safety Manual and Application
Application for duplicator D6038XA or D6038XB
D6038XA
or
D6038XB
(Ch.1 and Ch.2)
OFF operation ON operation
Field Input: proximity is OFF
or switch is open
Channel 1
D6038XA
or
D6038XB
(Ch.1 and Ch.2)
Field Input: proximity is ON
or switch is closed
Channel 1
1
2 Out 1
7
8
In 1
7
8
In 1
Supply
24 Vdc
5 + 6 -
Supply
24 Vdc
5 + 6 -
Out 1 resistance value is RL (for
direct function) or RH (for reverse
function)
Out 1 resistance value is RH (for
direct function) or RL (for reverse
function)
Safety
PLC
Input
1
2 Out 1
Safety
PLC
Input
As Out 1, Out 2 resistance value
is RH (for direct function) or RL
(for reverse function)
3
4 Out 2
Safety
PLC
Input
Channel 2 Output
3
4 Out 2
As Out 1, Out 2 resistance value
is RL (for direct function) or RH
(for reverse function)
Safety
PLC
Input
Channel 2 Output
Description:
For this application, for Channel 1 enable input line fault (open or short) detection and choose direct or reverse input to output transfer function, by set the internal dip-switches in the
following mode (for more information, please see the instruction manual ISM0431):
The module is powered by connecting 24 Vdc power supply to Pins 5 (+ positive) - 6 (- negative). The green LED is lit in presence of supply power.
Input signal from field is applied to Pins 7-8 (In 1 - Ch.1). Output Pins 1-2 (for Channel 1) and Output Pins 3-4 (for Channel 2) have got RH (direct function) or RL (reverse function)
resistance value for OFF operation, while they have got RL (direct function) or RH (reverse function) resistance value for ON operation. The following table describes for Channel 1
and Channel 2 the output resistance value when Channel 1 input signal is in OFF or ON state, and it gives information about turn-on or turn-off of Channel 1 status LED and
Channel 1 fault LED:
Dip-switch position 1 2 3 4
ON/OFF state ON OFF (direct) or ON (reverse) Not used Not used
Input 1 signal state
Pins 7-8 (In 1 - Ch.1)
Out 1 or Out 2 resistance value
Pins 1-2 (Out 1 - Ch.1) or Pins 3-4 (Out 2 - Ch.2)
Ch.1 status
yellow LED state
Ch.1 fault
red LED state
Proximity sensor is OFF or switch is open RH (direct function) or RL (reverse function) OFF (direct function)
ON (reverse function) OFF
Proximity sensor is ON or switch is closed RL (direct function) or RH (reverse function) ON (direct function)
OFF (reverse function) OFF
Independently from proximity sensor or switch state, input line is broken RH (direct or reverse function) as safe state condition OFF (direct or reverse
function) ON
Independently from proximity sensor or switch state, input line is short circuited RH (direct or reverse function) as safe state condition OFF (direct or reverse
function) ON
Safety Function and Failure behavior:
D6038X is considered to be operating in Low Demand mode, as a Type A module, having Hardware Fault Tolerance (HFT) = 0.
For each output channel, the failure behaviour is described from the following definitions :
□fail-Safe State: it is defined as two cases: 1st) the channel output being open, with output resistance equal or bigger than RH ; 2nd) the channel output being in short circuit,
with output resistance equal to zero or very little than RL. The module output must be monitored by a Digital Input channel of a Safety PLC in order to detect open circuit (very
high resistance) or short circuit (very low resistance) of output channel;
□fail Safe: failure mode that causes the module / (sub)system to go to the defined Fail-Safe state without a demand from the process;
□fail Dangerous: failure mode that does not respond to a demand from the process (i.e. being unable to go to the defined Fail-Safe state), so that the channel output is blocked
in closed position, with output resistance equal or less than RL, but not equal to short circuit therefore not detectable by a Digital Input channel of a Safety PLC;
□fail “No Effect”: failure mode of a component that plays a part in implementing the safety function but that is neither a safe failure or a dangerous failure.
When calculating the SFF this failure mode is not taken into account;
□fail “Not part”: failure mode of a component which is not part of the safety function but part of the circuit diagram and is listed for completeness.
When calculating the SFF this failure mode is not taken into account. It is also not considered for the total failure rate (safety function) evaluation.
Failure rate date: taken from Siemens Standard SN29500.
Failure category Failure rates (FIT)
λdd = Total Dangerous Detected failures 0.00
λdu = Total Dangerous Undetected failures 10.40
λsd = Total Safe Detected failures 0.00
λsu = Total Safe Undetected failures 206.20
λtot safe = Total Failure Rate (Safety Function) = λdd + λdu + λsd + λsu 216.60
MTBF (safety function, one channel) = (1 / λtot safe) + MTTR (8 hours) 527 years
λno effect = “No Effect” failures 225.00
λnot part = “Not Part” failures 202.90
λtot device = Total Failure Rate (Device) = λtot safe + λno effect + λnot part 644.50
MTBF (device) = (1 / λtot device) + MTTR (8 hours) 177 years
λsd λsu λdd λdu SFF
0.00 FIT 206.20 FIT 0.00 FIT 10.40 FIT 95.2%
Failure rates table according to IEC 61508:2010 Ed.2 :
Failure rate table:
T[Proof] = 1 year T[Proof] = 2 years
PFDavg = 4.56 E-05 Valid for SIL 3 PFDavg = 9.13 E-05 Valid for SIL 3
PFDavg vs T[Proof] table (assuming Proof Test coverage of 99%), with determination of SIL supposing module contributes >10% of total SIF dangerous failures:
PFDavg vs T[Proof] table (assuming Proof Test coverage of 99%), with determination of SIL supposing module contributes ≤10% of total SIF dangerous failures:
T[Proof] = 5 years
PFDavg = 2.28 E-04 Valid for SIL 3
SC3: Systematic capability SIL 3.

D6038 - SIL3 Line-Fault Transp. Switch/Prox. RepeaterG.M. International ISM0433-0 5
Testing procedure at T-proof
The proof test shall be performed to reveal dangerous faults which are undetected by diagnostic. This means that it is necessary to specify how dangerous undetected fault,
which have been noted during the FMEDA, can be detected during proof test.
Note for switch input: to detect a broken wire, or a short circuit condition, in the input connections it is necessary to mount, close to the switches, the end of line resistors:
R1=1 KΩtypical (470 Ωto 2 KΩrange) resistor in series and R2=10 kΩtypical (5 KΩto 15 KΩrange) resistor in parallel to the contacts.
The Proof test consists of the following steps:
Steps Action
1 Bypass the safety-related PLC or take other appropriate action to avoid a false trip.
2 For each channel, change the state conditions of the input sensors/contacts coming from field and verify, by ohmmeter connect to output terminals, that output
resistance change value from RL to RH or vice versa (according to direct or reverse function setting up by Dip-switches). RL and RH measured values must be
equivalent to RL and RH values within ±5% tolerance, defined on related product instruction manual .
3 For each channel, if input line fault detection is enable by Dip-switches specific set up, disconnect the input wiring coming from the field sensor/contact and check,
by ohmmeter connect to output terminals, that output resistance goes to RH value. Then, put in short condition the input connections and verify again that output
resistance goes to RH value. RH measured values must be equivalent to RH values within ±5% tolerance, defined on related product instruction manual.
In both case the related channel alarm LED, on the front panel, must be turned on with red light.
4 Restore the loop to full operation.
5 Remove the bypass from the safety-related PLC or restore normal operation.
This test will reveal approximately 99 % of possible Dangerous Undetected failures in the repeater.