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

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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.

Functional Safety KFD2-SR3-(Ex)2.2S
Planning
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3.3 Safety Function and Safe State
Safe State
The safe state of output I and output II is the de-energized state.
Safety Function
The safety function has two modes of operation:
• normal operation (output follows input)
• inverted operation (output inverts input)
Observe that only one input and one output are part of the same safety function in
the 2-channel version.
DIP Switch Settings
Line Fault Detection
For use in a safety function enable the line fault detection.
The input loop of all versions is supervised. The related safety function is that the
outputs go to fault state (safe state) if a line fault is detected.
Reaction Time
The reaction time for the safety function is < 20 ms.
Function Mode KFD2-SR3-2.2S,
KFD2-SR3-Ex2.2S
Mode channel I normal mode S1 position I
inverted mode S1 position II
Mode channel II normal mode S2 position I
inverted mode S2 position II
Line fault detection ON S3 position I
OFF
1
1
This switch setting may not be used if the device is used for safety relevant applications.
S3 position II
Table 3.1
Note!
The collective error message output is not safety relevant.

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Functional Safety KFD2-SR3-(Ex)2.2S
Planning
3.4 Characteristic Safety Values
The characteristic safety values like PFD, PFH, SFF, HFT and T
1
are taken from
the FMEDA report. Observe that PFD and T
1
are related to each other.
The function of the devices has to be checked within the proof test interval (T
1
).
Parameters acc. to IEC 61508 Characteristic values
Assessment type and documentation Full assessment
Device type A
Mode of operation Low demand mode or high demand mode
HFT 0
SIL (SC) 2
Safety function Normal/inverted operation

s1
145 FIT

dd
4.1 FIT

du
73 FIT

total (safety function)1
1
"No effect failures" and "Annunciation failures" are not influencing the safety function and are therefore not
included in the SFF and the safety values of the safety function.
222 FIT

not part
77 FIT
SFF
1
67 %
MTBF
2
2
acc. to SN29500. This value includes failures which are not part of the safety function/MTTR = 24 h. The
value is calculated for one safety function of the device.
270 years
PFH 7.26 x 10
-8
1/h
PFD
avg
for T
1
= 1 year 3.18 x 10
-4
PFD
avg
for T
1
= 2 years 6.36 x 10
-4
PFD
avg
for T
1
= 5 years 1.59 x 10
-3
PTC 100 %
Table 3.2

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Planning
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3.5 Useful Lifetime
Although a constant failure rate is assumed by the probabilistic estimation this
only applies provided that the useful lifetime of components is not exceeded.
Beyond this useful lifetime, the result of the probabilistic estimation is
meaningless as the probability of failure significantly increases with time. The
useful lifetime 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 operating 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 lifetime of each component.
It is assumed that early failures are detected to a huge percentage during the
installation and therefore the assumption of a constant failure rate during the
useful lifetime is valid.
However, according to IEC/EN 61508-2, a useful lifetime, based on general
experience, should be assumed. Experience has shown that the useful lifetime
often lies within a range period of about 8 ... 12 years.
As noted in DIN EN 61508-2:2011 note N3, appropriate measures taken by the
manufacturer and plant operator can extend the useful lifetime.
Our experience has shown that the useful lifetime of a Pepperl+Fuchs product
can be higher
• if there are no components with reduced life time in the safety loop (for
example electrolytic capacitors, relays, flash memories, optocoupler) which
can produce dangerous undetected failures and
• if the ambient temperature is significantly below 60 °C.
Please note that the useful lifetime refers to the (constant) failure rate of the
device. The effective life time can be higher.
Maximum Switching Power of Output Contacts
The useful lifetime is limited by the maximum switching cycles of the relays under
load conditions.
Note!
For more information see the corresponding datasheets.

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Functional Safety KFD2-SR3-(Ex)2.2S
Mounting and Installation
4 Mounting and Installation
Installing the device
1. Observe the safety instructions in the instruction manual.
2. Observe the information in the manual.
3. Observe the requirements for the safety loop.
4. Connect the device only to devices that are suitable for this safety application.
5. Check the safety function to ensure the expected output behavior.
4.1 Configuration
Configuring the Device
The device is configured via DIP switches. The DIP switches for setting the safety
functions are on the front of the device.
1. De-energize the device before configuring the device.
2. Open the cover.
3. Configure the device for the required safety function via the DIP switches,
see chapter 3.3.
4. Close the cover.
5. Secure the DIP switches to prevent unintentional adjustments.
6. Connect the device again.
Note!
For more information see the corresponding datasheets.
Functional Safety KFD2-SR3-(Ex)2.2S

Functional Safety KFD2-SR3-(Ex)2.2S
Operation
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5Operation
Operating the device
1. Observe the safety instruction in the instruction manual.
2. Observe the information in the manual.
3. Use the device only with devices that are suitable for this safety application.
4. Correct any occurring safe failures within 24 hours. Take measures to
maintain the safety function while the device is being repaired.
5.1 Proof Test
According to IEC/EN 61508-2 a recurring proof test shall be undertaken to reveal
potential dangerous failures that are not detected otherwise.
Check the function of the subsystem at periodic intervals depending on the
applied PFD
avg
in accordance with the characteristic safety values.
See chapter 3.4.
It is under the responsibility of the plant operator to define the type of proof test
and the interval time period.
Equipment required:
• Digital multimeter with an accuracy of 0.1 %
Use for the proof test of the intrinsic safety side of the device a special digital
multimeter for intrinsically safe circuits.
If intrinsically safe circuits are operated with non-intrinsically safe circuits,
they must no longer be used as intrinsically safe circuits.
• Power supply set to nominal voltage of 24 V DC
• Load resistor i. e. 240 , 2.5 W
• Simulate the sensor state by a potentiometer of 4.7 k(threshold for normal
operation), by a resistor of 220 (short circuit detection) and by a resistor of
150 k(lead breakage detection).
Danger!
Danger to life from missing safety function
If the safety loop is put out of service, the safety function is no longer guaranteed.
• Do not deactivate the device.
• Do not bypass the safety function.
• Do not repair, modify, or manipulate the device.
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Functional Safety KFD2-SR3-(Ex)2.2S
Operation
Check the settings after the configuration by suitable tests.
Proof Test Procedure
1. Test each input channel individually. The threshold must be between 1.4 mA
and 1.9 mA. The hysteresis must be between 170 A and 250 A.
For normal mode of operation the relay of the corresponding output must
have switched, if the input current is above the threshold. This state is
indicated by yellow LED.
For inverse mode of operation the relay of the corresponding output must
have switched, if the input current is below the threshold. This state is
indicated by yellow LED.
2. Connect a resistor R
SC
(220 ) or a resistor R
LB
(150 k) to the input.
The device must detect an external fault. This state is indicated by red
LED and the relay of the corresponfding output must be de-activated.
3. Test the outputs with a certain current, i. e. 100 mA and a voltage set to
24 V DC. Test that the contatcs of the relais are definitely open, if the relay is
de-activated.
4. Set back the device to the original settings for the current application after the
test.
5. Secure the DIP switches to prevent unintentional adjustments.
Figure 5.1 Proof test set-up for KFD2-SR3-(Ex)2.2S
Usage in Zone 0, 1, 2/Div. 1, 2 only for KFD2-SR3-Ex2.2S.
Zone 0, 1, 2
Div. 1, 2
KFD2-SR3-(Ex)2.2S
Multimeter
(mA)
RLB RSC
Multimeter
(mA)
RLB RSC
Multimeter
(mA)
240 Ω/2.5 W
24 V DC
Multimeter
(mA)
240 Ω/2.5 W 24 V DC
Multimeter
(mA)
240 Ω/2.5 W
24 V DC
Multimeter
(mA)
240 Ω/2.5 W 24 V DC
2+
3-
1+ 7
8
9
10
11
12
5+
6-
4+
Fault
Zone 2
Div. 2
Supply +
Supply -
24 V DC
Power
supply
I supply
Supply
Bus

Functional Safety KFD2-SR3-(Ex)2.2S
Maintenance and Repair
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6 Maintenance and Repair
Maintaining, Repairing or Replacing the Device
In case of maintenance, repair or replacement of the device, proceed as follows:
1. Implement appropriate maintenance procedures for regular maintenance of
the safety loop.
2. Ensure the proper function of the safety loop, while the device is maintained,
repaired or replaced.
If the safety loop does not work without the device, shut down the application.
Do not restart the application without taking proper precautions.
Secure the application against accidental restart.
3. Do not repair a defective device. A defective device must only be repaired by
the manufacturer.
4. Replace a defective device only by a device of the same type.
Danger!
Danger to life from missing safety function
If the safety loop is put out of service, the safety function is no longer guaranteed.
• Do not deactivate the device.
• Do not bypass the safety function.
• Do not repair, modify, or manipulate the device.
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Functional Safety KFD2-SR3-(Ex)2.2S
List of Abbreviations
7 List of Abbreviations
ESD Emergency Shutdown
FIT Failure In Time in 10
-9
1/h
FMEDA Failure Mode, Effects, and Diagnostics Analysis

s
Probability of safe failure

dd
Probability of dangerous detected failure

du
Probability of dangerous undetected failure

no effect
Probability of failures of components in the safety loop that have
no effect on the safety function. The no effect failure is not used
for calculation of SFF.

not part
Probability of failure of components that are not in the safety loop

total (safety function)
Safety function
HFT Hardware Fault Tolerance
MTBF Mean Time Between Failures
MTTR Mean Time To Restoration
PCS Process Control System
PFD
avg
Average Probability of dangerous Failure on Demand
PFH Average frequency of dangerous failure
PTC Proof Test Coverage
SFF Safe Failure Fraction
SIF Safety Instrumented Function
SIL Safety Integrity Level
SIL (SC) Safety Integrity Level (Systematic Capability)
SIS Safety Instrumented System
T
1
Proof Test Interval
FLT Fault
LB Lead Breakage
LFD Line Fault Detection
SC Short Circuit
Functional Safety KFD2-SR3-(Ex)2.2S

Functional Safety KFD2-SR3-(Ex)2.2S
Notes
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Pulscon LTC50 HART

Subject to modifications
Copyright PEPPERL+FUCHS • Printed in Germany
www.pepperl-fuchs.com
PROCESS AUTOMATION –
PROTECTING YOUR PROCESS
Worldwide Headquarters
Pepperl+Fuchs GmbH
68307 Mannheim · Germany
Tel. [phone]
E-mail: [email protected]
For the Pepperl+Fuchs representative
closest to you check www.pepperl-fuchs.com/contact
DOCT-5022
03/2016