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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