Pepperl+Fuchs KFD0-CS 54 Series User manual

ISO9001
2
Functional Safety
Repeater
KFD0-CS-(Ex)*.54*,
KFD0-CS-(Ex)*.56*
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 KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*

Functional Safety KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
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 Relevant Standards and Directives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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Functional Safety KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
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 KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
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 KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
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 KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
Product Description
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2 Product Description
2.1 Function
General
The device is a current repeater that transfers a current signal from the control system to
the field device. The device may be mounted in Zone 2 explosion hazardous area.
The device is loop powered with a low voltage drop and permits detection of line faults by
the control system.
Devices with designation "Ex" are used for intrinsic safety applications. Devices without
the designation "Ex" are signal conditioners.
An open field circuit presents a high impedance to the control side to allow alarm conditions
to be monitored by control systems.
Additionally, the device transfers AC signals from the field device to the control system.
This transfer can be used as safety-relevant information channel for an alarm system.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
KFD0-CS-(Ex)*.54*
The device repeats a 1 mA to 20 mA input signal from the control system to drive fire
and smoke alarms on the field side.
KFD0-CS-(Ex)*.56*
The device repeats a 1 mA to 40 mA input signal from the control system to drive
SMART I/P converters, valve actuators, and displays on the field side.
2.2 Interfaces
The device has the following interfaces.
• Safety-relevant interfaces:
• 1-channel devices: input I, output I
• 2-channel devices: input I, input II, output I, output II
• Non-safety-relevant interfaces: none
Note!
For corresponding connections see datasheet.

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Functional Safety KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
Product Description
2.3 Marking
The following obsolete devices are excluded from this evaluation.
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
KFD0-CS-Ex1.54, KFD0-CS-Ex1.54-Y*, KFD0-CS-Ex2.54,
KFD0-CS-Ex1.56, KFD0-CS-Ex2.56
Up to SIL 2
KFD0-CS-Ex1.54-Y72221 Part number 072221
KFD0-CS-Ex1.54 Part number 107496
KFD0-CS-Ex2.54 Part number 107497
Functional safety IEC/EN 61508, part 2, edition 2000:
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 KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
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 KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
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 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 application program in the safety logic solver is designed such that all currents below
1 mA or above 40 mA (20 mA for KFD0-CS-Ex*.54*) are detected and lead to the safe
state.
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.
• 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 Adevice,
the SFF must be > 60 % according to table 2 of IEC/EN 61508-2 for a SIL 2 (sub) system.
Exclusion
• The following obsolete devices are excluded from this evaluation.
KFD0-CS-Ex1.54-Y72221 Part number 072221
KFD0-CS-Ex1.54 Part number 107496
KFD0-CS-Ex2.54 Part number 107497

Functional Safety KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
Planning
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3.3 Safety Function and Safe State
Safety Function
The device has 2 safety functions.
• Safety-relevant communication:
• The device can maintain the safety-relevant communication.
• Enough voltage is available to supply the connected alarm devices in the alarm state.
• Analog current signal transfer:
Enough voltage is available to supply the connected alarm devices while communication
is not relied on.
Safe State
• Safety-relevant communication:
The alarm system communication fails and this communication failure is detected.
• Analog current signal transfer:
The supply fails and this failure is detected.
Reaction Time
The reaction time for all safety functions is:
•50s for .54 versions
•250s for .56 versions
Note!
See corresponding datasheets for further information.

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Functional Safety KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
Planning
3.4 Characteristic Safety Values
The characteristic safety values like PFD, SFF, HFT and T1are taken from
the SIL report/FMEDA report. Observe that PFD and T1are related to each other.
The function of the devices has to be checked within the proof test interval (T1).
Parameters Characteristic values
Assessment type and
documentation
FMEDA report
Device type A
Mode of operation Low Demand Mode or High Demand Mode
HFT 0
SIL (SC) 2 1
Safety function Safety-relevant communication Analog current signal transfer
s60 FIT 0 FIT
dd 0 FIT 34.0 FIT
du 5.7 FIT 34.2 FIT
total (safety function) 132 FIT 68 FIT
no effect 66 FIT 58 FIT
not part 16.0 FIT 22.2 FIT
SFF 95.6 % 49 %
PTC 100 % 100 %
MTBF 1
1acc. to SN29500. This value includes failures which are not part of the safety function/MTTR = 8 h. The value is calculated for
one safety function of the device.
770 years 770 years
PFH 5.74 x 10-9 1/h 3.40 x 10-8 1/h
PFDavg for T1= 1 year 2.50 x 10-5 1.49 x 10-4
PFDavg for T1= 2 years 5.02 x 10-5 2.98 x 10-4
PFDavg for T1= 5 years 1.26 x 10-4 7.49 x 10-4
Reaction time 2
2Time between fault detection and fault reaction
•50s for .54 versions
•250s for .56 versions
Table 3.1

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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 to 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 the ambient conditions support a long life time, for example 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.

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Functional Safety KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
Mounting and Installation
4 Mounting and Installation
Mounting and 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
A configuration of the device is not necessary and not possible.

Functional Safety KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
Operation
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5Operation
Operating the device
1. Observe the safety instructions 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 8 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 PFDavg
in accordance with the characteristic safety values provided. 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.
With the following instructions a proof test can be performed which will reveal all of the possible
dangerous faults (diagnostic coverage 100 %).
Equipment required:
• Digital multimeter with an accuracy better than 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.
• Variable power supply 0 V DC to 24 V DC
• Process calibrator with current source/sink function (mA) with an accuracy better
than 20 µA
Proof Test Procedure
1. Disconnect the field circuit.
2. Check the device as shown in the following tables.
3. After check reset the device to the necessary settings.
4. Connect the field circuit again.
5. Check the correct behavior of the safety loop. Is the configuration correct?
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 KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
Operation
Figure 5.1 Proof test set-up for KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
Channel 2 only for KFD0-CS-(Ex)2.54*, KFD0-CS-(Ex)2.56*.
Usage in Zone 0, 1, 2/Div. 1, 2 only for Ex versions
Step no. Set voltage
input value (V)
Set current
sink value
(mA)
Measurement point
Output
voltage (V)
.54 versions
Output
voltage (V)
.54-Y2 versions
Output
voltage (V)
.54-Y3 versions
Output
voltage (V)
.56 versions
124.00 0.00 22.75 ±0.75 22.75 ±0.75 22.75 ±0.75 n. a.
224.00 4.00 21.00 ±0.50 20.00 ±0.30 21.50 ±0.50 n. a.
324.00 20.00 16.00 ±2.00 8.15 ±0.35 15.40 ±0.40 n. a.
426.00 20.00 n. a. n. a. 17.00 ±0.50 n. a.
526.00 2.40 n. a. n. a. 23.90 ±0.20 n. a.
619.00 0.00 n. a. n. a. n. a. 18.60 ±0.30
719.00 10.00 n. a. n. a. n. a. 16.90 ±0.60
Table 5.1 Steps to be performed for the proof test
KFD0-CS-Ex2.5**
Zone 2
Div. 2
Zone 0, 1, 2
Div. 1, 2
2-
1+ 11+
12-
V
9+
10-
8-
5-
4+
I
II
mA
Multimeter
(V)
mA
Multimeter
(V)
V

Functional Safety KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
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 KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
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
sProbability 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) Probability of failure of components that are in the safety loop
HFT Hardware Fault Tolerance
MTBF Mean Time Between Failures
MTTR Mean Time To Restoration
PCS Process Control System
PFDavg Average Probability of dangerous Failure on Demand
PFH Average frequency of dangerous failure
PLC Programmable Logic Controller
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
T1Proof Test Interval

Functional Safety KFD0-CS-(Ex)*.54*, KFD0-CS-(Ex)*.56*
Notes
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Subject to modifications
Copyright PEPPERL+FUCHS • Printed in Germany
www.pepperl-fuchs.com
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
PROCESS AUTOMATION –
PROTECTING YOUR PROCESS
DOCT-4072A
06/2018