Functional Safety Relay Module KFD2-RSH-1.2E.L2 (-Y1), KFD2-RSH-1.2E.L3 (-Y1)
Functional Safety Relay Module KFD2-RSH-1.2E.L2 (-Y1), KFD2-RSH-1.2E.L3 (-Y1)
Relay Module
KFD2-RSH-1.2E.L2(-Y1),
KFD2-RSH-1.2E.L3(-Y1)
Manual
3
ISO9001
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"
Worldwide
Pepperl+Fuchs Group
Lilienthalstr. 200
68307 Mannheim
Germany
Phone: +49 621 776 - 0
E-mail: info@de.pepperl-fuchs.com
North American Headquarters
Pepperl+Fuchs Inc.
1600 Enterprise Parkway
Twinsburg, Ohio 44087
USA
Phone: +1 330 425-3555
E-mail: sales@us.pepperl-fuchs.com
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Pepperl+Fuchs Pte. Ltd.
P+F Building
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Singapore 139942
Phone: +65 6779-9091
E-mail: sales@sg.pepperl-fuchs.com
https://www.pepperl-fuchs.com
Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Content of this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Symbols Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Standards and Directives for Functional Safe . . . . . . . . . . . . . . . . . . . . . 9
3 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 System Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Safety Function and Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Characteristic Safety Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Useful Lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Internal Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Proof Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3 Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Contents
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Introduction
1 Introduction
Note
For full information on the product, refer to the instruction manual and further documentation
on the Internet at www.pepperl-fuchs.com.
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Introduction
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 KFD2-RSH-1.2E.L*(-Y1)
Introduction
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:
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-RSH-1.2E.L*(-Y1)
Product Description
2 Product Description
2.1 Function
General
This signal conditioner provides the galvanic isolation between field circuits
and control circuits.
The energized to safe (ETS) function is permitted for SIL 3 applications.
An internal fault or a line fault is signalized by the impedance change of the relay contact input
and an additional relay contact output.
A fault is signalized by LEDs and a separate collective error message output.
KFD2-RSH-1.2E.L2(-Y1)
The device is a relay module that is suitable for safely switching applications of a load circuit.
The device isolates load circuits up to 60 V DC and the 24 V DC control circuit.
KFD2-RSH-1.2E.L3(-Y1)
The device is a relay module that is suitable for safely switching applications of a load circuit.
The device isolates load circuits up to 230 V AC and the 24 V DC control circuit.
Y1 Version
This device is compatible to the following control: Emerson DeltaV CHARM.
Compatibility check to other ESD/DCS systems on request.
2.2 Interfaces
The device has the following interfaces:
• Safety-relevant interfaces: input, output (ETS)
• Non-safety relevant interfaces: fault indication output
Note
For corresponding connections see datasheet.
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Product Description
2.3 Marking
Pepperl+Fuchs Group
Lilienthalstraße 200, 68307 Mannheim, Germany
Internet: www.pepperl-fuchs.com
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Planning
3 Planning
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Planning
3.2 Assumptions
The following assumptions have been made during the FMEDA:
• Failure rates are constant, wear is not considered.
• Failure rate based on the Siemens standard SN 29500.
• The safety-related device is considered to be of type A device with a hardware
fault tolerance of 0.
• 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 nominal voltage at the digital input is 24 V. Ensure that the nominal voltage
does not exceed 26.4 V under all operating conditions.
• To achieve the safe state even in the case of an internal device fault, the DO card
must be able to supply a signal current of at least 100 mA.
• Observe the useful lifetime limitations of the output relays.
SIL 3 application
• To build a SIL safety loop for the defined SIL, it is assumed as an example that this device
uses 10 % of the available budget for PFDavg/PFH.
• For a SIL 3 application operating in low demand mode the total PFDavg value
of the SIF (Safety Instrumented Function) should be smaller than 10-3,
hence the maximum allowable PFDavg value would then be 10-4.
• For a SIL 3 application operating in high demand mode the total PFH value
of the SIF should be smaller than 10-7 per hour, hence the maximum allowable PFH value
would then be 10-8 per hour.
• For a SIL 3 application operating in high demand mode the internal fault detection
and the line fault detection must be enabled. The fault indication output,
the collective error message output, or the input impedance change must be monitored.
In case of detected faults the necessary reaction must be introduced.
• If the device is used in applications for high demand mode, perform a risk analysis
regarding systematic faults and implement suitable measures to control these systematic
faults. For example, this can be the following measures:
• usage of redundant power supplies,
• monitoring of input signal, wiring and connections for short circuits and open circuits,
• monitoring the output for open circuits.
• 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-RSH-1.2E.L*(-Y1)
Planning
Safe State
In the safe state of the safety function the ETS output is closed (conducting).
Reaction Time
The fault reaction time is < 2 s.
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Planning
1 "No effect failures" are not influencing the safety function and are therefore not included in SFF and in the failure rates
of the safety function.
2 While the diagnostic function is signaling the dangerous failure of one relay, the other two redundant relays continue to provide
the safety function. Exceptions are common cause failures that disrupt all three relays. While the diagnostic function is signaling
the failure, the probability of a dangerous undetected failure for the remaining two relays is increasing to 11.4 FIT.
3 acc. 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.
4
Enable the internal fault detection to achieve a diagnostic coverage of 81.2 %. See chapter 5.1.
5 Since the current PTC value is < 100 % and therefore the probability of failure will increase, calculate the PFD value according
to the following formula:
PFDavg = (du / 2) x (PTC x T1 + (1 – PTC) x Tservice)
A service time Tservice of 10 years was assumed for the calculation of PFDavg.
6 assuming 10 % of the PFDavg budget in the safety loop, T1 = Tservice
7
Step response time, also valid under fault conditions (including fault detection and fault reaction)
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Planning
The characteristic safety values like PFD, PFH, SFF, HFT and T1 are taken
from the FMEDA report. Observe that PFD and T1 are related to each other.
The function of the devices has to be checked within the proof test interval (T1).
Derating
For the safety application, reduce the number of switching cycles or the maximum current.
A derating to 2/3 of the maximum value is adequate.
Note
See corresponding datasheets for further information.
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Mounting and Installation
4.1 Mounting
Tighten the terminal screws with a torque of 0.5 ... 0.6 Nm.
4.2 Configuration
Note
The device configuration via DIP switches is not safety relevant.
Note
See corresponding datasheets for further information.
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Operation
5 Operation
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 KFD2-RSH-1.2E.L*(-Y1)
Operation
or
• Check the output function at periodic intervals. Switch on the output at least three times a
year as described in the steps 1 and 2.
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1 In this case only use a safety PLC with digital output and line fault detection.
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Operation
Conditions
KFD2-RSH-1.2E.L2(-Y1) KFD2-RSH-1.2E.L3(-Y1)
Load power supply > 5 V DC > 35.5 V AC
Device power supply (LED 24 V DC 24 V DC
PWR is on)
Output load 13.2 < R < 7.3 k 39.2 < R < 45 k
Current through load 14 mA < I < 1.9 A 13.5 mA AC < I < 4.9 A AC
Input current 36 mA 36 mA
Table 5.1
If the conditions are met, you can also check the device in the application.
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Operation
1. Enable the internal fault detection and the line fault detection. See chapter 4.2.1.
2. Check the device as shown in the following tables.
3. After check reset the device to the necessary settings.
4. Check the correct behavior of the safety loop. Is the configuration correct?
1
When the FLT LED flashes, a line fault is present. Check whether the supply voltage and the connected load are in the OK area
of the line fault detection.
When the FLT LED is lit continuously, an internal fault is present. Reset the internal fault by interrupting the power supply
(terminals 14+/15-).
Only if all tests are successfully done, the proof test is successful.
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Operation
KFD2-RSH-1.2E.L2(-Y1)
KFD2-RSH-1.2E.L3(-Y1)
5+ 7+
ETS 8- V
3 10
11
2-
14+
15-
24 V DC
Fault 24 V DC
Power Rail Zone 2
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Operation
KFD2-RSH-1.2E.L2
KFD2-RSH-1.2E.L3
5+ 7+
ETS 8- V
3 10
11
2-
14+
15-
24 V DC
Fault 24 V DC
Power Rail Zone 2
Figure 5.2 Application with fault indication output in the signal loop of the dual pole switching
If the fault indication output is open, the output relay contacts cannot be enabled.
But as the fault is detected by the process control system a suitable reaction can be planned.
The user must ensure that a suitable reaction on this detected fault is implemented.
For this application, the characteristic safety values are the same. The characteristic safety
values can be found in Table 3.1.
Warning!
Possible failure of the safety function
If a fault is detected, all output relay contacts remain open.
Take suitable measures in case the diagnosis is triggered. Take suitable measures to sustain
the safety function via the process control system.
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
Maintenance and Repair
1. Implement appropriate maintenance procedures for regular maintenance of the safety loop.
2. While the device is maintained, repaired or replaced, the safety function does not work.
Take appropriate measures to protect personnel and equipment while the safety function
is not available.
Secure the application against accidental restart.
3. Do not repair a defective device. A defective device must only be repaired by the manufacturer.
4. If there is a defect, always replace the device with an original device.
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Functional Safety KFD2-RSH-1.2E.L*(-Y1)
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
s Probability 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.
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 per hour
PLC Programmable Logic Controller
PTC Proof Test Coverage
SC Systematic Capability
SFF Safe Failure Fraction
SIF Safety Instrumented Function
SIL Safety Integrity Level
SIS Safety Instrumented System
T1 Proof Test Interval
Tservice Time from start of operation to putting the device out of service
DTS De-energized To Safe (sicherheitsgerichtetes Abschalten)
ETS Energized To Safe (sicherheitsgerichtetes Anschalten)
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