Pepperl+Fuchs KFD2-CD-1.32 Series User manual

ISO9001
2
Functional Safety
Current/Voltage Driver
KFD2-CD-(Ex)1.32-**
PROCESS AUTOMATION
MANUAL

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-CD-(Ex)1.32-**

Functional Safety KFD2-CD-(Ex)1.32-**
Content
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1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Content of this Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Symbols Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Proof Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Functional Safety KFD2-CD-(Ex)1.32-**
Introduction
1Introduction
1.1 Content of this Document
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:
• Present document
• Instruction manual
•Manual
•Datasheet
Additionally, the following parts may belong to the documentation, if applicable:
• EU-type examination certificate
• EU declaration of conformity
• Attestation of conformity
• Certificates
• Control drawings
• FMEDA report
• Assessment report
• Additional documents
For more information about Pepperl+Fuchs products with functional safety, 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-CD-(Ex)1.32-**
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.

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Functional Safety KFD2-CD-(Ex)1.32-**
Introduction
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.
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-CD-(Ex)1.32-**
Product Description
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2 Product Description
2.1 Function
KFD2-CD-1.32
This signal conditioner provides the galvanic isolation between field circuits and control
circuits.
The device supplies 2-wire transmitters.
The device transfers a current signal from the control side to I/P converters, electrical valves
and positioners located in the field side.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
KFD2-CD-Ex1.32-**
This isolated barrier is used for intrinsic safety applications.
The device supplies 2-wire transmitters.
The device transfers a voltage or a current signal from the non-hazardous area to
I/P converters, electrical valves and positioners located in the hazardous area.
The device is designed to provide various inputs and outputs of voltage and current.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
2.2 Interfaces
The device has the following interfaces.
• Safety relevant interfaces:
• Non-safety relevant interfaces: none
Input, output KFD2-CD-1.32
KFD2-CD-Ex1.32-0, KFD2-CD-Ex1.32-1, KFD2-CD-Ex1.32-3,
KFD2-CD-Ex1.32-6, KFD2-CD-Ex1.32-10, KFD2-CD-Ex1.32-12,
KFD2-CD-Ex1.32-13, KFD2-CD-Ex1.32-15, KFD2-CD-Ex1.32-21
Note!
For corresponding connections see datasheet.

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Functional Safety KFD2-CD-(Ex)1.32-**
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
Internet: www.pepperl-fuchs.com
KFD2-CD-1.32
KFD2-CD-Ex1.32-0, KFD2-CD-Ex1.32-1, KFD2-CD-Ex1.32-3,
KFD2-CD-Ex1.32-6, KFD2-CD-Ex1.32-10, KFD2-CD-Ex1.32-12,
KFD2-CD-Ex1.32-13, KFD2-CD-Ex1.32-15, KFD2-CD-Ex1.32-21
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-CD-(Ex)1.32-**
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 T1value (proof test interval that has a direct impact on the PFDavg value)
• the SFF value (Safe Failure Fraction)
• the HFT architecture (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
• the SFF value (Safe Failure Fraction)
• the HFT architecture (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-CD-(Ex)1.32-**
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 safety-related device is considered to be of type Adevice with a hardware
fault tolerance of 0.
• The device will be used under average industrial ambient conditions comparable
to the classification "stationary mounted" according to MIL-HDBK-217F.
Alternatively, operating stress conditions typical of an industrial field environment similar
to IEC/EN 60654-1 Class C with an average temperature over a long period of time of
40 ºC may be assumed. 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.
• For cases in which the connected field device detects a too high output signal, the failure
rate fail high may be subtracted from the dangerous undetected failure rate du and regarded
in a different way. If a reaction is introduced that brings the application to the safe state,
then the failure rate fail high can be added to the dangerous detected failure rate dd
or to the safe failure rate s.
• The connected field device must be set to its safe state if the output of the field device
reached a value below the specified valid range for the safety application.
For field devices with current output, this value is 3.6 mA. For field devices with
voltage output, this value is 0.9 V or 1.8 V.
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 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 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.
• Since the safety loop has a hardware fault tolerance of 0and it is a type Adevice,
the SFF must be > 60 % according to table 2 of IEC/EN 61508-2 for a SIL 2 (sub) system.