Pepperl+Fuchs KFD2-RSH-1.2D.FL2 User manual

ISO9001
PL e
3
Functional Safety
Relay Module
KFD2-RSH-1.2D.FL2,
KFD2-RSH-1.2D.FL3
PROCESS AUTOMATION
ORIGINAL INSTRUCTIONS

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-RSH-1.2D.FL2, KFD2-RSH-1.2D.FL3

Functional Safety KFD2-RSH-1.2D.FL2, KFD2-RSH-1.2D.FL3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Standards and Directives for Functional Safe. . . . . . . . . . . . . . . . . . . . 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 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Internal Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Proof Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3 Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Functional Safety KFD2-RSH-1.2D.FL2, KFD2-RSH-1.2D.FL3
Introduction
1Introduction
1.1 Content of this Document
This document contains safety-relevant information for usage of the device. 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!
For full information on the product, refer to the further documentation on the Internet at
www.pepperl-fuchs.com.

Functional Safety KFD2-RSH-1.2D.FL2, KFD2-RSH-1.2D.FL3
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-RSH-1.2D.FL2, KFD2-RSH-1.2D.FL3
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-RSH-1.2D.FL2, KFD2-RSH-1.2D.FL3
Product Description
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2 Product Description
2.1 Function
General
This signal conditioner provides the galvanic isolation between field circuits and control
circuits.
The de-energized to safe (DTS) function is permitted for SIL 3 and PL e applications.
An internal fault or a line fault is signalized by the impedance change of the relay contact input
and an additional relay contact output.
A fault is signalized by LEDs and a separate collective error message output.
The output must be protected against contact welding by an internal fuse or an external current
limitation.
KFD2-RSH-1.2D.FL2
The device is a relay module that is suitable for safely switching applications of a load circuit.
The device isolates load circuits up to 60 V DC and the 24 V DC control circuit.
KFD2-RSH-1.2D.FL3
The device is a relay module that is suitable for safely switching applications of a load circuit.
The device isolates load circuits up to 230 V AC and the 24 V DC control circuit.
2.2 Interfaces
The device has the following interfaces:
• Safety-relevant interfaces: input, output (DTS)
• Non-safety relevant interfaces: fault indication output
2.3 Marking
Note!
For corresponding connections see datasheet.
Pepperl+Fuchs GmbH
Lilienthalstraße 200, 68307 Mannheim, Germany
Internet: www.pepperl-fuchs.com
KFD2-RSH-1.2D.FL2, KFD2-RSH-1.2D.FL3 Up to SIL 3 and PL e

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Functional Safety KFD2-RSH-1.2D.FL2, KFD2-RSH-1.2D.FL3
Product Description
2.4 Standards and Directives for Functional Safe
Device-specific standards and directives
Functional safety IEC/EN 61508, part 1 –2, edition 2010:
Functional safety of electrical/electronic/programmable
electronic safety-related systems (manufacturer)
Machinery Directive
2006/42/EC
• EN/ISO 13849, part 1, edition 2015:
Safety-related parts of control systems (manufacturer)
• IEC 62061, edition 2005 + A1:2012 + A2:2015
EN 62061, edition 2005 + Cor. 2010 + A1:2013 + A2:2015:
Safety of machinery –Functional safety of safety-related
electrical, electronic and programmable electronic control
systems

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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-RSH-1.2D.FL2, KFD2-RSH-1.2D.FL3
Planning
3.2 Assumptions
The following assumptions have been made during the FMEDA:
• Failure rates are constant, wear is not considered.
• Failure rate based on the Siemens standard SN29500.
• 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.The nominal voltage at the digital input is 24 V.
Ensure that the nominal voltage do not exceed 26.4 V under all operating conditions.
• The DO card must be able to supply a signal current of at least 100 mA.
• Observe for the high demand mode the useful lifetime limitations of the output relays.
• The relay contacts must be protected against overcurrent with a suitable current limitation.
For this purpose, either the internal fuse or an external current limitation with the same limit
values must be used.
SIL 3 application
• The device shall claim less than 10 % of the total failure rate for a SIL 3 safety loop.
• For a SIL 3 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 SIL 3 application operating in high demand mode 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 safety loop has a hardware fault tolerance of 0and it is a type Adevice, the
SFF must be > 90 % according to table 2 of IEC/EN 61508-2 for a SIL 3 (sub) system.
SILCL and PL application
• The device was qualified for use in safety functions acc. to IEC/EN 62061 and
EN/ISO 13849-1. The device fulfils the requirements for a SILCL of SIL 3 acc. to
IEC/EN 62061 and due to the equivalency between these standards PL e acc. to
EN/ISO 13849-1.