Pepperl+Fuchs KFD2-SH-Ex1, KFD2-SH-Ex1.T, KFD2-SH-Ex1.OP, KHA6-SH-Ex1 Original Instructions Manual

PL d

3

PROCESS AUTOMATION

ORIGINAL INSTRUCTIONS

Functional Safety

Switch Amplifier
KFD2-SH-Ex1(.T)(.OP),
KHA6-SH-Ex1

Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

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-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Content

1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 Symbols Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 Safety Function and Safe State . . . . . . . . . . . . . . . . . . . . . . . . 11

3.4 Characteristic Safety Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.5 Useful Life Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.1 Proof Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6 List of evaluated Sensors . . . . . . . . . . . . . . . . . . . . . . . . 22

7 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 23

8 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Introduction

1Introduction

1.1 Contents

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

Note!

For full information on the product, refer to the further documentation on the
Internet at www.pepperl-fuchs.com.

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 of examination

• EU declaration of conformity

• Attestation of conformity

• Certificates

• Control drawings

• FMEDA report

• Assessment report

• Additional documents

For more information about functional safety products from Pepperl+Fuchs see
www.pepperl-fuchs.com/sil.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Introduction

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.

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.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Introduction

Depending on the risk level, the warning messages are displayed in descending
order as follows:

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.

Informative Symbols

Note!

This symbol brings important information to your attention.

Action

This symbol indicates a paragraph with instructions. You are prompted to perform
an action or a sequence of actions.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Product Description

2 Product Description

2.1 Function

General

The devices are safety components according to the machinery directive
2006/42/EC.

This isolated barrier is used for intrinsic safety applications.

The device transfers digital signals (SN/S1N proximity sensors or approved dry
contacts) from a hazardous area to a safe area.

Unlike an SN/S1N series proximity sensor, a mechanical contact requires a
10 k resistor to be placed across the contact in addition to a 1.5 k resistor in
series.

Lead breakage (LB) and short circuit (SC) conditions of the control circuit are
continuously monitored.

During an fault condition, the fault indication output energizes and outputs I and II
de-energize.

For safety applications up to SIL 3, output I must be used. For safety applications
up to SIL 2, output I and output II can be used.

The device is designed for mounting on a 35 mm DIN mounting rail according to
EN 60715.

KFD2-SH-Ex1, KHA6-SH-Ex1

The input controls 1 relay contact output with 3 NO contacts (1 output is in series
to the both output relays for the safety function), 1 relay contact output with
1 NO contact, and 1 passive transistor output (fault indication output).

KFD2-SH-Ex1.T

The input controls 1 active voltage output and 1 relay contact output with a
NO contact.

KFD2-SH-Ex1.T.OP

The input controls 1 active voltage output and 1 relay contact output with a
NO contact.

The device can only be supplied by Power Rail.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Product Description

2.2 Interfaces

The device has the following interfaces.

• Safety relevant interfaces: input, output I, output II

• Non-safety relevant interfaces: fault indication output, power supply

Note!

For corresponding connections see datasheet.

2.3 Marking

Pepperl+Fuchs GmbH
Lilienthalstraße 200, 68307 Mannheim, Germany

Internet: www.pepperl-fuchs.com

KFD2-SH-Ex1, KFD2-SH-Ex1.T, KFD2-SH-Ex1.T.OP,
KHA6-SH-Ex1

Up to SIL 3
Up to PL d

2.4 Standards and Directives for Functional Safety

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/EN 62061,
edition 2005 + A1:2012/2013 + A2:2015:

Safety of machinery – Functional safety of safety-

related electrical, electronic and programmable
electronic control systems

System-specific standards and directives

Functional safety IEC/EN 61511, part 1, edition 2003:

Functional safety – Safety instrumented systems for

the process industry sector (user)

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Planning

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:

•the PFD
the T

• the SFF value (Safe Failure Fraction)

•the HFT architecture (Hardware Fault Tolerance)

value (average Probability of dangerous Failure on Demand) and

avg

value (proof test interval that has a direct impact on the PFD

1

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:

• 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)

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 = (

+ dd) / (s + dd + du)

s

avg

value)

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-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Planning

3.2 Assumptions

The following assumptions have been made during the FMEDA:

• The fault indication output which signals if the field circuits are broken or
shorted is not considered in the FMEDA and the calculations.

• For output I of the KFD2-SH-Ex1 and KHA6-SH-Ex1 devices, use the
3 redundant relay contacts to establish the necessary redundancy.

• 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 A device with a hardware
fault tolerance of 0.

• Observe for the high demand mode the useful lifetime limitations of the output
relays.

• The device will be used under average industrial ambient conditions, which
are comparable with the classification "stationary mounted" in MIL-HDBK­217F. Alternatively, the following ambient conditions are assumed:

• IEC/EN 60654-1 Class C (sheltered location) with temperature limits in the

range of the manufacturer's specifications and an average temperature of

40 ºC over a long period. The humidity level is within manufacturer's rating.
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.

SIL 3 application

If you use output I of the device, you can reach SIL 3 according to IEC 61508.

• 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 PFD
of the SIF (Safety Instrumented Function) should be smaller than 10
the maximum allowable PFD

value would then be 10-4.

avg

value

avg

-3

, hence

• For a SIL 3 application operating in high demand mode the total PFH value of
the SIF should be smaller than 10
PFH value would then be 10

-7

-8

per hour.

per hour, hence the maximum allowable

• Since the safety loop has a hardware fault tolerance of 0 and it is a type A
device, the SFF must be > 90 % according to table 2 of IEC/EN 61508-2 for a
SIL 3 (sub) system.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Planning

SIL 2 application

If you use output I or output II of the device, you can reach SIL 2 according to
IEC 61508.

• 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 PFD
of the SIF (Safety Instrumented Function) should be smaller than 10
the maximum allowable PFD

• For a SIL 2 application operating in high demand mode the total PFH value of
the SIF should be smaller than 10
PFH value would then be 10

• Since the safety loop has a hardware fault tolerance of 0 and it is a type A
device, the SFF must be > 60 % according to table 2 of IEC/EN 61508-2 for a
SIL 2 (sub) system.

PL d application

• If you use output I of the device, you can use the device in safety control loops
up to performance level PL d.

• The devices were qualified for use in applications acc. to EN/ISO 13849-1.
They fulfill PL d and are designed as Category 3 equipment. Consider the
rules for use given in this standard.

value would then be 10-3.

avg

-6

-7

per hour, hence the maximum allowable

per hour.

value

avg

-2

, hence

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Planning

3.3 Safety Function and Safe State

Safe State

The safe state of the outputs is the de-energized state. This state is reached when
the input is in low state.

Safety Function

K***-SH-Ex1

The devices have two outputs that can be used for the safety function. Output I is
a relay output with triplicated output relay, intended for use in applications up to
SIL 3 or PL d. Output II is an additional relay output that may by itself be used in
applications up to SIL 2.

KFD2-SH-Ex1.T(.OP)

The devices have two outputs that can be used for the safety function. Output I is
an electronic output that may be used in applications up to SIL 3 or PL d. Output II
may be used in applications up to SIL 2.

Line Fault Detection

The input circuit of all versions is supervised. The related safety function is
defined as the outputs are low/de-energized (safe state), if a line fault or a short
circuit of the sensor is detected.

Reaction Time

The reaction time for all safety functions is < 30 ms.

Note!

The fault indication output is not safety relevant.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Planning

3.4 Characteristic Safety Values

KHA6-SH-Ex1

Parameters acc. to IEC 61508 Characteristic values

Assessment type and

FMEDA, proven-in-use assessment, certificate

documentation

Device type A

Mode of operation Low Demand Mode or High Demand Mode

HFT 0

1

0

SIL 3 (proven-in-use) 2 (proven-in-use)

Safety function Output I is de-energized when

input in low state



s



du



dd





2

no effect

total (safety function)

266 FIT 179 FIT

0.6 FIT 51.9 FIT

76.8 FIT 50.4 FIT

190 FIT 143 FIT

289 FIT 280 FIT

Output II is de-energized when
input in low state

SFF 99.8 % 81 %

3

MTBF

MTTF

DC

d

B10

d

d

214 years 269 years

1477 years –

99.2 % (high) –

250000 –

Category (ISO 13849-1) 3 –

PL d –

PFH 6.47 x 10

PFD

for T1 = 1 year 2.83 x 10

avg

PFD

for T1 = 2 years 5.67 x 10

avg

PFD

for T1 = 5 years 1.42 x 10

avg

Reaction time

4

< 30 ms < 30 ms

-10

1/h 5.19 x 10-8 1/h

-6

-6

-5

2.27 x 10

4.55 x 10

1.14 x 10

-4

-4

-3

Table 3.1

1

The redundant relays can be considered as elements with hardware fault tolerance. For this calculation the
redundant relays were considered as "diagnostics" for the relay with a DC value of 99 % to take care of a
possible common cause failure.

2

"Annunciation failures" are not directly influencing the safety functions and are therefore added to the 



3

acc. to SN29500. This value is calculated with the failure rates of the device components which are part of the

no effect

value.

safety function of the device.

4

Time between fault detection and fault reaction.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Planning

KFD2-SH-Ex1

Parameters acc. to IEC 61508 Characteristic values

Assessment type and

FMEDA, proven-in-use assessment, certificate

documentation

Device type A

Mode of operation Low Demand Mode or High Demand Mode

HFT 0

1

0

SIL 3 (proven-in-use) 2 (proven-in-use)

Safety function Output I is de-energized when

input in low state



s



du



dd





2

no effect

total (safety function)

237 FIT 203 FIT

0.6 FIT 51.9 FIT

50.5 FIT 36.6 FIT

215 FIT 156 FIT

288 FIT 291 FIT

Output II is de-energized when
input in low state

SFF 99.8 % 82 %

3

MTBF

MTTF

DC

d

B10

d

d

204 years 254 years

2240 years –

98.7 % (medium) –

250000 –

Category (ISO 13849-1) 3 –

PL d –

PFH 6.47 x 10

PFD

for T1 = 1 year 2.83 x 10

avg

PFD

for T1 = 2 years 5.67 x 10

avg

PFD

for T1 = 5 years 1.42 x 10

avg

Reaction time

4

< 30 ms < 30 ms

-10

1/h 5.19 x 10-8 1/h

-6

-6

-5

2.27 x 10

4.55 x 10

1.14 x 10

-4

-4

-3

Table 3.2

1

The redundant relays can be considered as elements with hardware fault tolerance. For this calculation the
redundant relays were considered as "diagnostics" for the relay with a DC value of 99 % to take care of a
possible common cause failure.

2

"Annunciation failures" are not directly influencing the safety functions and are therefore added to the 

no effect

value.



3

acc. to SN29500. This value is calculated with the failure rates of the device components which are part of the
safety function of the device.

4

Time between fault detection and fault reaction.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Planning

KFD2-SH-Ex1.T(.OP)

Parameters acc. to IEC 61508 Characteristic values

Assessment type and

FMEDA, proven-in-use assessment, certificate

documentation

Device type A

Mode of operation Low Demand Mode or High Demand Mode

HFT 0

SIL 3 (proven-in-use) 2 (proven-in-use)

Safety function Output I is de-energized when

input in low state



s



du



dd





1

no effect

total (safety function)

181 FIT 194 FIT

1.4 FIT 51.6 FIT

38.4 FIT 38.4 FIT

195 FIT 130 FIT

218 FIT 282 FIT

Output II is de-energized when
input in low state

SFF 99.4 % 81 %

2

MTBF

MTTF

DC

d

B10

d

d

275 years 276 years

2860 years –

96.5 % (medium) –

– –

Category (ISO 13849-1) 3 –

PL d –

PFH 1.38 x 10-9 1/h 5.16 x 10-8 1/h

PFD

for T1 = 1 year 6.04 x 10

avg

PFD

for T1 = 2 years 1.21 x 10

avg

PFD

for T1 = 5 years 3.02 x 10

avg

Reaction time

3

-6

-6

-5

2.26 x 10

4.52 x 10

1.13 x 10

< 30 ms < 30 ms

-4

-4

-3

Table 3.3

1

"Annunciation failures" are not directly influencing the safety functions and are therefore added to the 



2

acc. to SN29500. This value is calculated with the failure rates of the device components which are part of the

no effect

value.

safety function of the device.

3

Time between fault detection and fault reaction.

The characteristic safety values like PFD, PFH, SFF, HFT and T

are taken from

1

the FMEDA report and the assessment documentation created by the issuer.
Please note, PFD and T
has to be checked within the proof test interval (T

The safety values MTTF

are related to each other. The function of the devices

1

).

1

, DCd, Category and PL for the machinery directive are

d

taken from the assessment report and certificate.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Planning

3.5 Useful Life Time

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 KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

1

0

I (A)

2

30

100502010

200 U (V)

500

Resistive load
AC

Resistive load
DC

0.5

0.2

0.1

Electrical life
max. 10

5

switching cycles

1

0

I (A)

2

30

100502010

200

253

U (V)500

Resistive load
AC

Resistive load
DC

0.5

0.2

0.1

Electrical life
max. 10

5

switching cycles

1

0

I (A)

2

48

100502010

200 U (V)

500

Resistive load
AC/DC

0.5

0.2

0.1

Electrical life
max. 10

5

switching cycles

0.25

Planning

Maximum Switching Power of Output Contacts KFD2-SH-Ex1

Figure 3.1

Maximum Switching Power of Output Contacts KHA6-SH-Ex1

Figure 3.2

Maximum Switching Power of Output Contacts KFD2-SH-Ex1.T(.OP)

Figure 3.3

The maximum number of switching cycles is depending on the electrical load and
may be higher if reduced currents and voltages are applied.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Mounting and Installation

4 Mounting and Installation

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.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Operation

5Operation

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.

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 Procedure

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 PFD
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.

Equipment required:

• Digital multimeter with an accuracy better than 0.1 %
For the proof test of the intrinsic safety side of the devices, a special digital
multimeter for intrinsically safe circuits must be used.

Intrinsically safe circuits that were operated with non-intrinsically safe circuits
may not be used as intrinsically safe circuits afterwards.

• Power supply set at nominal voltage of 24 V DC.

• Potentiometer 4.7 k.

• Resistor 220 /150 k.

•Resistor 1.3 k/0.5 W (.T(.OP) version only).

•Resistor 1 k/1 W.

in accordance with the characteristic safety values. 

avg

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Operation

Proof Test Procedure

1. Prepare a test set-up, see figure below.

2. Simulate the state of the sensor

- by a potentiometer of 4.7 k (threshold for normal operation),

- by a resistor of 220  (short circuit detection) and

- by a resistor of 150 k (lead breakage detection)

3. Connect a load of 1.3 k to the voltage output of the .T(.OP) device.

4. Supply the relay contact output by 24 V DC externally. Connect an 1 k
resistor as load to the relay contact output. Test this configuration with a
multimeter for the state (on).

5. For versions with triplicated relays, test each single relay with a multimeter if
the off state is reached.

The input threshold must be between 2.1 mA and 2.8 mA. The hysteresis

must be between 170 µA and 250 µA (measured with input multimeter and

potentiometer).
If the input current is above the threshold,

- the voltage output must be activated, voltage level higher than 20 V DC
(.T(.OP) version only),

- the relay contact output must conduct (approx. 24 mA over 1 k),

- the yellow LED must be on.

6. For the functional safety it is important that the voltage output is definitely off
(less than 1 V DC) and each single relay contact output is definitely open
(high impedance), if the input is below the lower threshold (typ. 2.5 mA) or
above the higher threshold (typ. 6 mA).

7. Connect the resistor R

(220 ) or the resistor RLB (150 k) to the input.

SC

The red LED must indicate the fault, the voltage output is off, the relay

contact outputs are high impedant (> 100 k).

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Zone 0, 1, 2
Div. 1, 2

Zone 2

Div. 2

1 kΩ/1W

KFD2-SH-Ex1

16+

17-

13

19

14

20

15

21

II

FLT

I

12-

10+

R

LB

150 kΩ

R

SC

220 Ω

Multimeter

(Ω)

Multimeter

(Ω)

Multimeter

(I)

Multimeter

( I )

24 V DC

Multimeter

(Ω)

Multimeter

( I )

1 kΩ/1W

Multimeter

( I )

24 V DC

Supply +

Supply -

24 V DC

Power
supply

I supply

Supply

Bus

Supply +

Supply -

24 V DC

Power
supply

I supply

Supply

Bus

Zone 0, 1, 2
Div. 1, 2

Zone 2

Div. 2

R

LB

150 kΩ

R

SC

220 Ω

1 kΩ/1W

KFD2-SH-Ex1.T.OP

4+

6-

9

10
11

12

7+

8-

II

FLT

I

V

Multimeter

(I)

Multimeter

( I )

Multimeter

( U )

Multimeter

( I )

24 V DC

Supply +

Supply -

24 V DC

Power
supply

I supply

Supply

Bus

1.3 kΩ

Operation

Figure 5.1 Proof test set-up for KFD2-SH-Ex1, KHA6-SH-Ex1

Figure 5.2 Proof test set-up for KFD2-SH-Ex1.T(.OP)

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

List of evaluated Sensors

6 List of evaluated Sensors

The following sensors were evaluated for use in conjunction with PL d and SIL 3:

NJ2-11-SN

NJ2-11-SN-G

NJ2-11-SN-G-..M

NJ2-12GK-SN

NJ2-12GK-SN-..M

NJ4-12GK-SN

NJ4-12GK-SN-..M

NJ3-18GK-S1N

NJ3-18GK-S1N-..M

NJ5-18GK-SN

NJ5-18GK-SN-..M

NJ8-18GK-SN

NJ8-18GK-SN-..M

NJ6-22-SN

NJ6-22-SN-G

NJ6-22-SN-G-..M

NJ5-30GK-S1N

NJ5-30GK-S1N-..M

NJ10-30GK-SN

NJ10-30GK-SN-..M

NJ15-30GK-SN

NJ15-30GK-SN-..M

NJ6S1+U1+N1

NJ15S+U1+N

NJ20S+U1+N

NJ40-FP-SN-P1

SJ2-SN

SJ2-S1N

SJ3,5-SN

SJ3,5-SN-Y89604

SJ3,5-S1N

NCN3-F25-SN4-V1

PL2-F25-SN4-K

PL3-F25-SN4-K

1

1

1

1

1

1

1

1

1

1

Table 6.1

1

-..M means different cable lengths in meter (m).

Additionally, mechanical switches may be used. See chapter 2.1.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Maintenance and Repair

7 Maintenance and Repair

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.

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.

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

List of Abbreviations

8 List of Abbreviations

B

10d

Number of switching cycles of relays until 10 % of these
components have failed

Category Category acc. to EN/ISO 13849-1

DC

d

Diagnostic Coverage of dangerous faults

DCS Distributed Control System

ESD Emergency Shutdown

-9

FIT Failure In Time in 10

1/h

FMEDA Failure Mode, Effects and Diagnostics Analysis



s



dd



du



no effect

Probability of safe failure

Probability of dangerous detected failure

Probability of dangerous undetected failure

Probability of failures of components in the safety path that have
no effect on the safety function



not part



total (safety function)

Probability of failures of components that are not in the safety path

Safety function

HFT Hardware Fault Tolerance

MTBF Mean Time Between Failures

MTTF

d

Mean Time To dangerous Failures

MTTR Mean Time To Repair

PFD

avg

Average Probability of Failure on Demand

PFH Probability of dangerous Failure per Hour

PL Performance Level acc. to EN/ISO 13849-1

PTC Proof Test Coverage

SFF Safe Failure Fraction

SIF Safety Instrumented Function

SIL Safety Integrity Level

SIS Safety Instrumented System

T

1

Proof Test Interval

FLT Fault

LB Lead Breakage

LFD Line Fault Detection

SC Short Circuit

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Notes

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Notes

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Functional Safety KFD2-SH-Ex1(.T)(.OP), KHA6-SH-Ex1

Notes

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Subject to modifications
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DOCT-2992B

04/2017