Pepperl+Fuchs KFD2-SR3-2.2S User manual

Functional Safety
Switch Amplifier
KFD2-SR3-(Ex)2.2S
PROCESS AUTOMATION
MANUAL
ISO9001
2

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-SR3-(Ex)2.2S

Functional Safety KFD2-SR3-(Ex)2.2S
Content
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Safety Function and Safe State . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Characteristic Safety Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Useful Lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Proof Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Functional Safety Manual HiD2872, HiC2873(Y1), HiD2876, HiC2877

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Functional Safety KFD2-SR3-(Ex)2.2S
Introduction
1 Introduction
1.1 Contents
This document contains information for usage of the device in functional safety-
related applications. 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:
• EC-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!
This document does not substitute the instruction manual.
Note!
For full information on the product, refer to the instruction manual and further
documentation on the Internet at www.pepperl-fuchs.com.
Functional Safety KFD2-SR3-(Ex)2.2S

Functional Safety KFD2-SR3-(Ex)2.2S
Introduction
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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.

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Functional Safety KFD2-SR3-(Ex)2.2S
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-SR3-(Ex)2.2S
Product Description
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2ProductDescription
2.1 Function
General
Each input controls a relay contact output.
Via switches the mode of operation can be reversed and the line fault detection
can be switched off.
A fault is signalized by LEDs acc. to NAMUR NE44 and a separate collective error
message output.
If the device is operated via Power Rail, additionally a collective error message is
available.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
KFD2-SR3-2.2S
This signal conditioner provides the galvanic isolation between field circuits and
control circuits.
The device transfers digital signals (NAMUR sensors or dry contacts) from the
field to the control system.
KFD2-SR3-Ex2.2S
This isolated barrier is used for intrinsic safety applications.
The device transfers digital signals (NAMUR sensors or dry contacts) from a
hazardous area to a safe area.
2.2 Interfaces
The device has the following interfaces:
• Safety relevant interfaces: input I, input II, output I, output II
• Non-safety relevant interfaces: collective error message output
Note!
For corresponding connections see datasheet.
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Functional Safety KFD2-SR3-(Ex)2.2S
Product Description
2.3 Marking
2.4 Standards and Directives for Functional Safety
Device specific standards and directives
System-specific standards and directives
Pepperl+Fuchs GmbH
Lilienthalstraße 200, 68307 Mannheim, Germany
KFD2-SR3-2.2S, KFD2-SR3-Ex2.2S Up to SIL 2
Functional safety IEC/EN 61508, part 1 –7, edition 2010:
Functional safety of
electrical/electronic/programmable electronic
safety-related systems (manufacturer)
Functional safety IEC/EN 61511, part 1 –3, edition 2003:
Functional safety –Safety instrumented systems for
the process industry sector (user)

Functional Safety KFD2-SR3-(Ex)2.2S
Planning
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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 T
1
value (proof test interval that has a direct impact on the PFD
avg
value)
•theSFFvalue(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:
•thePFHvalue(Probability of dangerous Failure per Hour)
• Fault reaction time of the safety system
•theSFFvalue(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.
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Functional Safety KFD2-SR3-(Ex)2.2S
Planning
3.2 Assumptions
The following assumptions have been made during the FMEDA:
• 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 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.
• The fault indication output which signals if the field circuits are broken or
shorted is not considered in the FMEDA and the calculations.
• The indication of a dangerous failure (via fault bus) is detected within 1 hour by
the programmable logic controller (PLC).
SIL 2 Application
• The device shall claim less than 10 % of the total failure budget for a SIL 2
safety loop.
• For a SIL 2 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 SIL 2 application operating in high demand mode 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 safety-related device is considered to be of type Adevice with a hardware
fault tolerance of 0.
• Since the safety loop has a hardware fault tolerance of 0and it is a type A
device, the SFF must be > 60 % according to table 2 of IEC/EN 61508-2 for a
SIL 2 (sub) system.