Pepperl+Fuchs KCD2-SR-1.LB, KCD2-SR-1.SP, KCD2-SR-Ex1.SP, KCD2-SR-2, KCD2-SR-Ex2 Safety Manual
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SAFETY MANUAL SIL
Switch Amplifier
KCD2-SR-(Ex)*(.LB)(.SP),
HiC282*
PROCESS AUTOMATION
ISO9001
Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
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"
Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Contents
1 Introduction ........................................................................ 4
1.1 General Information ......................................................................................4
1.2 Intended Use ................................................................................................4
1.3 Manufacturer Information..............................................................................5
1.4 Relevant Standards and Directives...............................................................5
2 Planning .............................................................................. 6
2.1 System Structure ..........................................................................................6
2.1.1 Low Demand Mode of Operation .............................................................6
2.1.2 High Demand or Continuous Mode of Operation......................................6
2.1.3 Safe Failure Fraction ................................................................................6
2.2 Assumptions.................................................................................................7
2.3 Safety Function and Safe State.....................................................................8
2.4 Characteristic Safety Values.........................................................................9
3 Safety Recommendation ................................................. 10
3.1 Interfaces....................................................................................................10
3.2 Configuration ..............................................................................................10
3.3 Useful Life Time..........................................................................................10
3.4 Installation and Commissioning ..................................................................12
4 Proof Test.......................................................................... 13
4.1 Proof Test Procedure..................................................................................13
5 Abbreviations ................................................................... 16
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Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Introduction
1Introduction
1.1 General Information
This manual contains information for application of the device in functional safety
related loops.
The corresponding data sheets, the operating instructions, the system
description, the Declaration of Conformity, the EC-Type-Examination Certificate,
the Functional Safety Assessment and applicable Certificates (see data sheet)
are integral parts of this document.
The documents mentioned are available from www.pepperl-fuchs.com or by
contacting your local Pepperl+Fuchs representative.
Mounting, installation, commissioning, operation, maintenance and disassembly
of any devices may only be carried out by trained, qualified personnel. The
instruction manual must be read and understood.
When a fault is detected within the device, it must be taken out of service and
action taken to protect against accidental use. Devices shall only be repaired
directly by the manufacturer. De-activating or bypassing safety functions or failure
to follow the advice given in this manual (causing disturbances or impairment of
safety functions) may cause damage to property, environment or persons for
which Pepperl+Fuchs GmbH will not be liable.
The devices are developed, manufactured and tested according to the relevant
safety standards. They must only be used for the applications described in the
instructions and with specified environmental conditions, and only in connection
with approved external devices.
1.2 Intended Use
The devices are available as safe area version (KCD2-SR-*(.LB)(.SP)) where
they can be used as a signal conditioner providing isolation for non-intrinsically
safe applications. Also the devices are available as hazardous area version
(KCD2-SR-Ex*(.LB)(.SP), HiC282*) allowing use as isolated barriers for intrinsic
safety applications.
The safe area versions transfer digital signals (NAMUR sensors/mechanical
contacts) via a galvanic isolation. The hazardous area versions transfer these
signals from a hazardous to a safe area.
The proximity sensor or switch controls a normally open relay output for the safe
area load. The device output changes state when the input signal changes state.
The normal output state can be reversed via DIP switches.
In the KCD2-SR-(Ex)1.LB(.SP) versions, output II can be switched to either follow
output I or to detect faults on the input line (line break, short circuit).
Line fault detection (LFD) can be selected or disabled via a DIP switch.
During an error condition the outputs de-energize.
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Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Introduction
A fault is signalized by LEDs acc. to NAMUR NE44 and a separate collective error
message output.
The KC devices are available with screw terminals or spring terminals. The type
code of the versions of the KC-devices with spring terminals has the
extension ".SP".
The KCD2-SR-(Ex)*(.LB)(.SP) is a single device for DIN rail mounting while the
HiC282* is a plug-in device to be inserted into a specific Termination Board.
1.3 Manufacturer Information
Pepperl+Fuchs GmbH
Lilienthalstrasse 200, 68307 Mannheim, Germany
KCD2-SR-1.LB(.SP)
KCD2-SR-Ex1.LB(.SP)
KCD2-SR-2(.SP)
KCD2-SR-Ex2(.SP)
HiC2821, HiC2822
Up to SIL2
1.4 Relevant Standards and Directives
Device specific standards and directives
Functional safety IEC 61508 part 1 – 2, edition 2000:
Standard of functional safety of electrical/electronic/programmable electronic
safety-related systems (product manufacturer)
Electromagnetic compatibility:
- EN 61326-1:2006
- NE 21:2006
System specific standards and directives
Functional safety IEC 61511 part 1, edition 2003:
Standard of functional safety: safety instrumented systems for the process
industry sector (user)
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Safety Manual SIL KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Planning
2 Planning
2.1 System Structure
2.1.1 Low Demand Mode of Operation
If there are two 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:
the PFD
value (proof test interval that has a direct impact on the PFD
the SFF value (Safe Failure Fraction)
the HFT architecture (Hardware Fault Tolerance)
2.1.2 High Demand or Continuous Mode of Operation
If there is only one loop, which combines the standard operation and safety
related operation, then usually the demand rate for this loop is assumed to be
higher than once per year.
The relevant safety parameters to be verified are:
the PFH value (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 architecture)
2.1.3 Safe Failure Fraction
The safe failure fraction describes the ratio of all safe failures and dangerous
detected failures to the total failure rate.
SFF = (
A safe failure fraction as defined in 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.
value (average Probability of Failure on Demand) and the T
avg
+ dd) / (s + dd + du)
s
avg
proof
)
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