Danfoss Reliability Data (MTTF) Application guide

Functional Safety

Reliability Data (MTTF)

for PLUS+1 Microcontrollers and I/O
modules

www.danfoss.com

Functional Safety

Reliability data (MTTF) for MC and I/O modules

Revision history Table of revisions

Date Changed Rev

February 2020 Component and calculation summary chapter/topic MC050-010 added 0304

January 2020 Corrections made in Component and calculation summary 0303

December 2019 Component and calculation summary chapter/topic MC050-110 and MC050-118 replaced

MC050-110; Added row to Device total table with MC050-118 information

July 2016 First edition 0101

0201

2 | © Danfoss | February 2020 AB202286484713en-000304

Functional Safety

Reliability data (MTTF) for MC and I/O modules

Contents

Overview

Reliability Data (MTTF)....................................................................................................................................................................4

Standards and references

Introduction........................................................................................................................................................................................5

Assumptions.......................................................................................................................................................................................5

Standards.............................................................................................................................................................................................5

Calculations........................................................................................................................................................................................ 5

Component and calculation summary

MC012-110 and IOX012-110........................................................................................................................................................ 6

MC024-110..........................................................................................................................................................................................6

MC024-120 and IOX024-120........................................................................................................................................................ 7

MC024-130..........................................................................................................................................................................................7

MC050-010..........................................................................................................................................................................................8

MC050-110 and MC050-118.........................................................................................................................................................9

MC050-120....................................................................................................................................................................................... 10

MC050-155....................................................................................................................................................................................... 11

OX012-110........................................................................................................................................................................................11

OX024-110........................................................................................................................................................................................12

Terms and definitions

PFH and FIT.......................................................................................................................................................................................13

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Danfoss | February 2020 AB202286484713en-000304 | 3

Functional Safety

Reliability data (MTTF) for MC and I/O modules

Overview

Reliability Data (MTTF)

Transfer of Mean Time to Failure (MTTF) data for the given product from Danfoss to the appropriate party.
This Mean Time to Failure (MTTF) data has been compiled by the Business Area engineering team

responsible. These are professionals at Danfoss, who have the authority and technical knowledge to
calculate the MTTF Data for this product based on the standards set in place by both the industry and/or
Danfoss.

The purpose of this document is to assist in the transfer of MTTF data for the given product from Danfoss
to the appropriate party in a way which will result in a clear understanding and documentation on how
we derived it.

This MTTF data is provided to assist in calculating the overall MTTF of a complete or partially complete
piece of machinery. Danfoss cannot be held responsible for the suitability of these calculated MTTF
values for use in the calculation of the overall machinery MTTF values.

The MTTF values are based on a specific machine use, operating environment, and/or duty cycle as stated
by the standards set in place by both the industry and/or Danfoss.

This communication along with any attached Danfoss drawings, sketches, or data is transmitted in
confidence. No information stated in this document or any attachments or supplements may be
reproduced or disclosed in whole or in part without written permission of Danfoss. Further, neither these
documents nor any attachments are a warranty of any sort by Danfoss or a guarantee of machine
suitability for its intended purpose. It remains the responsibility of the machine manufacturer to ensure
overall machine functionality and overall machine safety.

4 | © Danfoss | February 2020 AB202286484713en-000304

Functional Safety

Reliability data (MTTF) for MC and I/O modules

Standards and references

Introduction

As of December 29, 2009, Machinery Directive 2006/42/EC is effective for all machinery placed on the
market in the European community. This directive mandates that machinery manufacturers are

responsible for performing and documenting a Hazard and Risk Assessment. Each identified risk must
then be addressed to ensure risk reduction to an acceptable risk level.

The processes to guide the execution of these activities are defined in various harmonized standards
such as:

•

ISO 12100:2010 Safety of Machinery

General principles for design

‒

Risk assessment and risk reduction

‒

•

ISO 13849 Safety of Machinery

Safety-related parts of control systems

‒

Danfoss adds value by participating in the machine manufacturers process and providing the appropriate
product information to enable the required probabilistic calculations.

Assumptions

The failure rate listed in this document is the result of a FMEDA analysis.
All failure rates were calculated using component data from MIL-HDBK-217F at 45°C, unless otherwise

noted. All failure mode distributions were taken from IEC 62061:2005 Annex D.
For inputs, a failure included in MTTFd and PFH is categorized as a mismatch between expected and

measured signal.
For logic and outputs, failure included in MTTFd and PFH is categorized as one that causes:

•

Loss of high-side switch turn-off capability

•

Uncommanded turn-on of high-side switch

•

A mismatch between commanded and actual current (for proportional outputs only)

Analysis should be performed, taking into account if not all components fail dangerously.

Standards

IEC 61508:2006
IEC 62061:2005 Annex D
MIL-HDBK-217F

Calculations

Probability does not consider CAN communication external issues.

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Danfoss | February 2020 AB202286484713en-000304 | 5

PLUS+1® microcontroller hardware category - Type B device

Failure modes and percentages

Reliability prediction of electronic equipment

Functional Safety

Reliability data (MTTF) for MC and I/O modules

Component and calculation summary

MC012-110 and IOX012-110

Inputs

Function (configuration) MTTF (years) MTTFd (years)

DIN/AIN/FREQIN (Digital) 4,827.50 6,595.80
DIN/AIN/FREQIN (Analog) 4,293.60 7,247.40
DIN/AIN/FREQIN (Frequency) 4,744.80 9,026.00
DIN/AIN/CANx SHIELD (Digital) 14,766.90 14,766.90
DIN/AIN/CANx SHIELD (Analog) 12,353.30 12,353.30

Common logic

Power and logic 195.90 220.10

Outputs

Function MTTF (years) MTTFd (years)

PWMOUT/DOUT/PVGOUT 1,074.20 1,074.20

MTTF (years) MTTFd (years)

MC024-110

Device total

MTTF (years) MTTF

129.10 144.90

*

Assume worst-case scenario when all failures are determined to be Dangerous and the failure causes any change in

device functionality.

*

(years)

d

Inputs

Function (configuration) MTTF (years) MTTFd (years)

DIN (Digital) 14,199.80 14,199.80
DIN/AIN/FREQIN (Digital) 4,827.50 6,595.80
DIN/AIN/FREQIN (Analog) 4,293.60 7,247.40
DIN/AIN/FREQIN (Frequency) 4,744.80 9,026.00
DIN/AIN/CANx SHIELD (Digital) 14,766.90 14,766.90
DIN/AIN/CANx SHIELD (Analog) 12,353.30 12,353.30
AIN/TEMP/RHEO (Digital) 8,165.50 8,165.50
AIN/TEMP/RHEO (Analog) 7,004.00 7,004.00
AIN/TEMP/RHEO (Rheostat) 4,406.50 4,406.50

Common logic

MTTF (years) MTTFd (years)

Power and logic 195.90 220.10

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Functional Safety

Reliability data (MTTF) for MC and I/O modules

Component and calculation summary

Outputs

Function MTTF (years) MTTFd (years)

PWMOUT/DOUT/PVGOUT 1,074.20 1,074.20

Device total

MTTF (years) MTTF

91.30 100.90

*

Assume worst-case scenario when all failures are determined to be Dangerous and the failure causes any change in

device functionality.

MC024-120 and IOX024-120

Inputs

Function (Configuration) MTTF (years) MTTFd (years)

DIN (Digital) 14,199.80 14,199.80
DIN/AIN/FREQIN (Digital) 4,827.50 6,595.80
DIN/AIN/FREQIN (Analog) 4,293.60 7,247.40
DIN/AIN/FREQIN (Frequency) 4,744.80 9,026.00
DIN/AIN/CANx SHIELD (Digital) 14,766.90 14,766.90
DIN/AIN/CANx SHIELD (Analog) 12,353.30 12,353.30

*

(years)

d

MC024-130

Common logic

MTTF (years) MTTFd (years)

Power and logic 195.90 220.10

Outputs

Function MTTF (years) MTTFd (years)

PWMOUT/DOUT/PVGOUT 1.074.20 1.074.20

Device total

MTTF (years) MTTF

75.50 80.10

*

Assume worst-case scenario when all failures are determined to be Dangerous and the failure causes any change in

device functionality.

*

(years)

d

Inputs

Function (Configuration) MTTF (years) MTTFd (years)

DIN (Digital) 14,199.80 14,199.80
DIN/AIN/FREQIN (Digital) 4,827.50 6,595.80
DIN/AIN/FREQIN (Analog) 4,293.60 7,247.40
DIN/AIN/FREQIN (Frequency) 4,744.80 9,026.00
DIN/AIN/CANx SHIELD (Digital) 14,766.90 14,766.90
DIN/AIN/CANx SHIELD (Analog) 12,353.30 12,353.30

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Danfoss | February 2020 AB202286484713en-000304 | 7

Functional Safety

Reliability data (MTTF) for MC and I/O modules

Component and calculation summary

Common logic

Power and logic 180.90 201.40

Outputs

Function MTTF (years) MTTFd (years)

PWMOUT/DOUT/PVGOUT 1,074.20 1,074.20

Device total

MTTF (years) MTTF

74.00 78.30

*

Assume worst-case scenario when all failures are determined to be Dangerous and the failure causes any change in

device functionality.

MC050-010

MTTF (years) MTTFd (years)

*

(years)

d

Assumptions: Diagnostic coverage and MTTFd were not calculated

All failure rates were calculated using MIL-HDBK-217F at 45°C unless otherwise noted.
All failure mode distributions were taken from IEC 62061:2005.
For inputs, a failure included in MTTFd and PFH is categorized as a mismatch between expected and

measured signal.
For logic and outputs, a failure included in MTTFd and PFH is categorized as any that causes:

1. loss of high-side switch turn-off capability, or

2. uncommanded turn-on of high-side switch, or

3. a mismatch between commanded and actual current (for proportional outputs only)

Inputs

Function (configuration)

DIN (Digital) D4 (Digital) 14,598.5
DIN/AIN (Digital) DA1 (Digital) 5,061.2
DIN/AIN (Analog) DA1 (Analog) 4,577.1
DIN/AIN/CANx SHIELD (Digital) DA3 (Digital) 11,630.8
DIN/AIN/CANx SHIELD (Analog) DA3 (Analog) 10,079.6
DIN/AIN/CANx SHIELD (Digital) DA3_B (Digital) 11,455.4
DIN/AIN/CANx SHIELD (Analog) DA3_B (Analog) 8,898.8
DIN/AIN/FREQIN (Digital) DAF1 (Digital) 6,509.7
DIN/AIN/FREQIN (Analog) DAF1 (Analog) 6,069.7
DIN/AIN/FREQIN (Frequency) DAF1 (Frequency) 10,057.9
DIN/AIN/ResIN (Digital) DAR2 (Digital) 5,711.3
DIN/AIN/ResIN (Analog) DAR2 (Analog) 4,913.5
DIN/AIN/ResIN (Rheostat) DAR2 (Rheostat) 4,553.9

Function (Configuration)
[internal name]

MTTF (years)

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Functional Safety

Reliability data (MTTF) for MC and I/O modules

Component and calculation summary

Power and Logic

Function (configuration)

Power and logic Power and Logic 146.4

Outputs

Function (Configuration)

PWMOUT PWM1 1,199.7
PWMOUT/DOUT/PVGOUT PWM2 1,069.7
DOUT DOUT2 11,606.2

Device total

IEC 61508
Safe Failure Fraction
[%]

S DD 50.3
DD DU
DU

*

SFF

Failure Category

DD = Dangerous Detected Failure
DU = Dangerous Undetected Failure
S = Safe Failure

*

SFF is the probablility of failing in a safe state.

**

DC is the ratio of the rate of detected dangerous failures compared to the rate of all dangerous failures

Function (Configuration)
[internal name]

Function (Configuration)
[internal name]

ISO 13849
Diagnostic Coverage
[%]

**

DC

MTTF (years)

MTTF (years)

MTTF
[years]

MC050-110 and MC050-118

Inputs

Function (configuration) MTTF (years) MTTFd (years)

DIN (Digital) 14,199.80 14,199.80
DIN/AIN (Digital) 5,452.10 5,452.10
DIN/AIN (Analog) 4,882.60 4,882.60
DIN/AIN/FREQIN (Digital) 4,827.50 6,595.80
DIN/AIN/FREQIN (Analog) 4,293.60 7,247.40
DIN/AIN/FREQIN (Frequency) 4,744.80 9,026.00
DIN/AIN/CANx SHIELD (Digital) 14,766.90 14,766.90
DIN/AIN/CANx SHIELD (Analog) 12,353.30 12,353.30
AIN/TEMP/RHEO (Digital) 8,165.50 8,165.50
AIN/TEMP/RHEO (Analog) 7,004.00 7,004.00
AIN/TEMP/RHEO (Rheostat) 4,406.50 4,406.50

Common Logic

MTTF (years) MTTFd (years)

Power and logic 157.20 172.40

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Functional Safety

Reliability data (MTTF) for MC and I/O modules

Component and calculation summary

Outputs

Function (Configuration) MTTF (years) MTTFd (years)

DOUT 8,218.40 8,218.40
DOUT/PVG PWR 4,717.30 4,717.30
PWMOUT/DOUT/PVGOUT 1,074.20 1,074.20

Device total

Controller MTTF (years) MTTF

MC050-110 49.10 51.90
MC050-118 48.6 51.4

*

Assume worst-case scenario when all failures are determined to be Dangerous and the failure causes any change in

device functionality.

MC050-120

Inputs

Function (configuration) MTTF (years) MTTFd (years)

DIN (Digital) 14,199.80 14,199.80
DIN/AIN (Digital) 5,452.10 5,452.10
DIN/AIN (Analog) 4,882.60 4,882.60
DIN/AIN/FREQIN (Digital) 4,827.50 6,595.80
DIN/AIN/FREQIN (Analog) 4,293.60 7,247.40
DIN/AIN/FREQIN (Frequency) 4,744.80 9,026.00
DIN/AIN/CANx SHIELD (Digital) 14,766.90 14,766.90
DIN/AIN/CANx SHIELD (Analog) 12,353.30 12,353.30
AIN/TEMP/RHEO (Digital) 8,165.50 8,165.50
AIN/TEMP/RHEO (Analog) 7,004.00 7,004.00
AIN/TEMP/RHEO (Rheostat) 4,406.50 4,406.50

*

(years)

d

Common logic

MTTF (years) MTTFd (years)

Power and logic 159.30 174.90

Outputs

Function (Configuration) MTTF (years) MTTFd (years)

DOUT 8,218.40 8,218.40
DOUT/PVG PWR 4,717.30 4,717.30
PWMOUT/DOUT/PVGOUT 1,074.20 1,074.20

Device total

MTTF (years) MTTF

60.40 64.80

*

Assume worst-case scenario when all failures are determined to be Dangerous and the failure causes any change in

device functionality.

*

(years)

d

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Functional Safety

Reliability data (MTTF) for MC and I/O modules

Component and calculation summary

MC050-155

Inputs

Function (configuration) MTTF (years) MTTFd (years)

DIN/AIN (Digital) 5,452.10 5,452.10
DIN/AIN (Analog) 4,882.60 4,882.60
DIN/AIN/FREQIN (Digital) 4,827.50 6,595.80
DIN/AIN/FREQIN (Analog) 4,293.60 7,247.40
DIN/AIN/FREQIN (Frequency) 4,744.80 9,026.00
DIN/AIN/CANx SHIELD (Digital) 14,766.90 14,766.90
DIN/AIN/CANx SHIELD (Analog) 12,353.30 12,353.30

Common logic

Power and logic 131.30 141.70

Outputs

Function (Configuration) MTTF (years) MTTFd (years)

DOUT 8,218.40 8,218.40
PWMOUT/DOUT/PVGOUT 1,074.20 1,074.20

MTTF (years) MTTFd (years)

OX012-110

Device total

MTTF (years) MTTF

59.80 63.40

*

Assume worst-case scenario when all failures are determined to be Dangerous and the failure causes any change in

device functionality.

*

(years)

d

Common logic

MTTF (years) MTTFd (years)

Power and logic 230.70 266.00

Outputs

Function (Configuration) MTTF (years) MTTFd (years)

PWMOUT/DOUT/PVGOUT 1,074.20 1,074.20

Device total

MTTF (years) MTTF

100.80 107.00

*

Assume worst-case scenario when all failures are determined to be Dangerous and the failure causes any change in

device functionality.

*

(years)

d

A risk assessment should be performed to define the right configuration of the Input/Output (I/O)
module.

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Danfoss | February 2020 AB202286484713en-000304 | 11

Functional Safety

Reliability data (MTTF) for MC and I/O modules

Component and calculation summary

The I/O modules can be configured to react in different ways to faulty conditions. For information about
configuration of the I/Ot modules, please see PLUS+1® Controller Family Technical Information, 520L0719
and HWD documentation.

OX024-110

Common logic

Power and logic 225.60 259.20

Outputs

Function (Configuration) MTTF (years) MTTFd (years)

DOUT 8,218.40 8,218.40
DOUT/PVG PWR 4,717.30 4,717.30
PWMOUT/DOUT/PVGOUT 1,074.20 1,074.20

Device total

MTTF (years) MTTF

68.30 71.00

*

Assume worst-case scenario when all failures are determined to be Dangerous and the failure causes any change in

device functionality.

MTTF (years) MTTFd (years)

*

(years)

d

A risk assessment should be performed to define the right configuration of the Input/Output (I/O)
module.

The I/O modules can be configured to react in different ways to faulty conditions. For information about
configuration of the I/Ot modules, please see PLUS+1® Controller Family Technical Information, 520L0719
and HWD documentation.

12 | © Danfoss | February 2020 AB202286484713en-000304

Functional Safety

Reliability data (MTTF) for MC and I/O modules

Terms and definitions

PFH and FIT

Failure rate per operational hour is also referred to as lambda.

PFH / lambda (Probability Failure Hour) = 1/MTTF (years) * 365 * 24
FIT (Failure In Time) = 1/MTTF (hours) * 10e-9

©

Danfoss | February 2020 AB202286484713en-000304 | 13

Danfoss
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