PT2E-30612

Smart transmitter/Gas Detector Head

SD-3
Safety Manual

Document Number: PT2E-306(Rev.12)[NOTE] The SD-3 is certified for functional safety (IEC 61508:2010 Part 2 and Part 3).
To ensure certified functionality, maintain the product as described in this document.

Revision history
Rev.

Details

Approved

CheckedCreated

KOGURE Shinsuke

MUTOU Hiroki

SAIKI Yuki

Jun 25, 2021

Jun 25, 2021

Jun 25, 2021

KOGURE Shinsuke

MUTOU Hiroki

SAIKI Yuki

Jun 25,2021

Jun 25,2021

Jun 25,2021

KOGURE Shinsuke

MUTOU Hiroki

SAIKI Yuki

2

Nov 16,2021

Nov 16,2021

Nov 16,2021

P8 2-4 Change Diagnosis response 15s -> 20s.

KOGURE Shinsuke

MUTOU Hiroki

SAIKI Yuki

Dec 2,2021

Dec 2,2021

Dec 2,2021

KOGURE Shinsuke

MUTOU Hiroki

SAIKI Yuki

Jun 28,2022

Jun 28,2022

Jun 28,2022

KOGURE Shinsuke

MUTOU Hiroki

SAIKI Yuki

Jan 10,2023

Jan 10,2023

Jan 10,2023

KOGURE Shinsuke

HIRAO Keisuke

SAIKI Yuki

Apr 27,2023

Apr 27,2023

Apr 27,2023

KOGURE Shinsuke

HIRAO Keisuke

SAIKI Yuki

May 17,2023

May 17,2023

May 17,2023

KOGURE Shinsuke

HIRAO Keisuke

SAIKI Yuki

Aug 4,2023

Aug 4,2023

Aug 4,2023

KOGURE Shinsuke

HIRAO Keisuke

SAIKI Yuki

Aug 10,2023

Aug 10,2023

Aug 10,2023

0

New document

1

Only rev up to match the Japanese version

Add SD-3EC2

3

P11 2-15 Product service life. Chang to the sensor
and Oter than the Sensor

3

P8 2-6 Proof test Add wording
P11 2-11 Reliability data update4

P12 2-19 H/W,S/W version update

4
P4 Change wording 1-1 Ambient conditions
P5 Add 1-3 Applicable standards

5

P6 Add Table 2 Environmental condition
P9 Add item in 2-3 Safety accuracy
P12 Update 2-11 Reliability data
P13 Add item 2-19 H/W S/W version

5

P12 Update 2-11 Reliability data

6

P13 Delete item and Version UP 2-19 H/W S/Wversion

6

P12 Update 2-11 Reliability data

7

7
P7 Change to Table2.Environmental condition

8

P13 Update 2-11 Reliability data
P14 Update 2-19 H/W S/W version

8

Change from “operating manual” to“SD-3 Series Export Specifications Technical
Manual for SIL and FM Specifications (PT2E-287)

9

rev.7”

9

Update 2-19 Identification of hardware/software
configurations
Update 2-11 Reliability data

2 / 17

Update note of Table2

10
Update 1-1 Ambient conditions

11
Update 1-1 Ambient conditions

12

10

11

12

Update 2-19 Identification of
hardware/software configurations

KOGURE Shinsuke

HIRAO Keisuke

SAIKI Yuki

Aug 16,2023

Aug 16,2023

Aug 16,2023

KOGURE Shinsuke

HIRAO Keisuke

SAIKI Yuki

Aug 17,2023

Aug 17,2023

Aug 17,2023

KOGURE Shinsuke

HIRAO Keisuke

SAIKI Yuki

Aug 21,2023

Aug 21,2023

Aug 21,2023

3 / 17

Contents
1

2

Purpose ........................................................................................................................... 5
1-1

Ambient conditions................................................................................................... 5

1-2

Regulations and applicable standards (functional safety) ....................................... 5

1-3

Applicable standards (other than functional safety standards) ............................... 6

1-4

Magnetic field threshold limit values (immunity level) ............................................. 7

Usage Instructions......................................................................................................... 9
2-1 Safety Functions ........................................................................................................... 9
2-2 Non-functional safety features...................................................................................... 9
2-3 Safety accuracy ........................................................................................................... 11
2-4 Diagnosis response ..................................................................................................... 11
2-5 Setup............................................................................................................................ 11
2-6 Proof test ..................................................................................................................... 11
2-7 Maintenance ............................................................................................................... 13
2-8 Repairs and replacements.......................................................................................... 13
2-9 Storage, Relocation, and Disposal ............................................................................. 13
2-10 Startup time (initialization time) ................................................................................ 13
2-11 Reliability data ........................................................................................................... 14
2-12 Operation mode ........................................................................................................ 14
2-13 Availability rate .......................................................................................................... 14
2-14 Power source ............................................................................................................ 14
2-15 Product service life ................................................................................................... 14
2-16 Requested parameter settings ................................................................................. 14
2-17 Limitations on installation and operating environments ........................................... 15
2-18 Application limitations ............................................................................................... 15
2-19 Identification of hardware/software configurations ................................................... 15
2-20 Product Specifications .............................................................................................. 15
2-21 Error codes and message ........................................................................................ 15
2-22 Operator interfaces ................................................................................................... 15
2-23 Prohibited items ........................................................................................................ 16
2-24 Terminology and abbreviations................................................................................. 16

4 / 17

Safety Manual

1

PurposeThis Safety Manual can be used at SIL2 in HFT 0 and SIL 3 in HFT 1. (SIL 3 Capable)
This document discusses topics for which the user is responsible if the SD-3 (this product), a
certified device, functions as or is part of a configuration functioning as a safety instrument.
These topics include proof testing, repairs and replacement, reliability data, product service
life, environmental limitations, operational limitations, and various parameters. To ensure
product safety, carefully read this document and all related documents.

This product monitors combustible gases, toxic gases, and oxygen concentrations at
sampling points.
This safety device is designed to prevent gas-related accidents and injury by outputting acurrent (4 - 20 mA) to indicate the gas concentrations detected.
Classified as a sensor (subsystem) for safety devices, this product outputs 4 - 20 mA current
according to the gas concentrations detected, or HART protocol signals when requested by
the upstream system, to a logic section of the upstream system.
This product was developed for use as a single sensor in a SIL2 loop (IEC 61508).
1-1

Ambient conditions

2

5

Operating temperature range: -40 to +70 °C (no sudden changes)

Absolute Maximum temperature range
Operating humidity range:-45 to +75 °C (no sudden changes): 10 to 90 %RH (no condensation)

Storage temperature range: -10 to +40 °C (no sudden changes)

Storage humidity range: 10 to 90 %RH (no condensation)

See Table 2. for SD-3EC and SD-3ECB
1-2Regulations and applicable standards (functional safety)
IEC 61508:2010 Parts 1 to 7
Functional Safety of Electrical/Electronic/Programmable Electronic
Safety-Related Systems

5 / 1711

1-3

Applicable standards (other than functional safety standards)

Japanese explosion-proof

5

EMC related
IECEx standards

5

ATEX related

Performance related

HART

General provisions in 2015 technologicalstandards
Flameproof enclosures in technologicalstandard 2018
EN 50270:2015 (Type 2)
BS EN 50270:2015 (Type 2)
IEC 60079-0:2017
IEC 60079-1:2014
EN IEC 60079-0:2018
EN 60079-1:2014
BS EN IEC 60079-0:2018
BS EN 60079-1:2014
IEC/EN 60079-29-1
EN 45544-3
EN 50104
HART7

6 / 17

1-4

Magnetic field threshold limit values (immunity level)
EN 50270:2015 request level

Table 1 Immunity test requirements: EN 50270:2015 (Type 2)
Item
Test ProcedureSpecification
Electrostatic
EN±6 kV (CD: contact discharge)
discharges
61000-4-2:2009±8 kV (AD: air discharge)
Radio-frequency
EN
10 V/m: 80 – 1,000 MHz
electromagnetic field 61000-4-3:2006
10 V/m: 1.4 - 2 GHz+A1:2008
3 V/m: 2 - 2.7 GHz+A2:2010
80 %AM, 1 kHz (unmodulated, rms)
Electrical fastEN
(DC power, earth line)transient/burst
61000-4-4:2004±2 kV (5/50 ns, 5 kHz)(DC power)+A1:2010(Earth line)(I/O Signal)(I/O signal)±1 kV (5/50 ns, 5 kHz)SurgesEN(DC power)(DC power)
61000-4-5:2006±2 kV (line to ground)(I/O signal)±1 kV (line to line)(1.2/50 (8/20) μs)(I/O signal)±1 kV (line to ground)(1.2/50 (8/20) μs)
0.15 - 80 MHz, 10 V (unmodulated,rms) 80 %AM, 1 kHz

Criteria
A
A

A

B

Radio-frequency
common mode
(I/O signal)
Power frequency
magnetic fieldEN
61000-4-6:2009
EN
61000-4-8:2010

50/60 Hz, 30 A/m (rms)A

Voltage dips

EN61000-4-29

C

Short interruptions

EN61000-4-29

0 % residual voltage / 1,000 ms
duration
40 % residual voltage / 1,000 ms
duration
0 % residual voltage / 20 ms duration

7 / 17AC

Table2．Environmental condition
Model

Gas
type

Operatingtemperature
range
※1

CO

-25～55℃

5

8

10

11

Absolute
Maximum
temperature
range※1

12
Operatinghumidityrange※1storageconditions
※1

note

-10℃～+40℃

ESF-A24P-30～60℃

20～90%RH

0％RH～

-

90%RH
-10℃～+40℃

ESF-A24R

H2S-25～55℃-30～60℃

20～90%RH

0％RH～

-

90%RH
-10℃～+40℃

ESF-B22NH3-25～55℃-30～60℃

30～80％RH

0％RH～

-

90%RH
-10℃～+40℃

ESF-A24A

NO2-25～55℃-30～60℃

20～90%RH

0％RH～

-

90%RH
-10℃～+40℃

ESF-X24P2

O2-25～55℃-30～60℃

20～90%RH

0％RH～

-

90%RH
-10℃～+40℃

ESF-C92CL2-20～55℃-25～60℃

30～80％RH

0％RH～

-

90%RH

※1

No sudden changes in temperature or condensation (no fluctuations of 10°C or more
per hour).
If the temperature fluctuates more than 10°C or more per hour, please use optional
accessories.

8 / 17

2

Usage Instructions

2-1 Safety Functions
The following items are the safety functions of this product.
• Monitors combustible gases, toxic gases, and oxygen concentrations at sampling points.
• Safe status means the current is output to the upstream system according to theconcentrations of the combustible gases, toxic gases, or oxygen being monitored. The
product outputs 4 - 20 mA signals and HART protocol signals (*).
• 4 - 20 mA output
The relationship between the measured gas concentrations and 4 - 20 mA output is
proportional. The output is 4 mA at F.S ×0 %, and when concentration is full scale, the output
is 20mA at F.S×100 %.
* HART output is not included in the safety functions.

2-2 Non-functional safety features
The following features are not functional safety features:• HART output• Contact output (optional)• RS485 output (optional)

9 / 17

System example
An example of a system that controls a solenoid valve via PLCs to create a shut off.

4 - 20 mA

PLC

SD-3

Solenoid
valve<SD-3>

Power supply
DV24V
24
V DC

SD-3

Signal output(4-20mA)(4– 20 mA)

Gas
Sensor<SD-3SC+GD-3>

Power supply
DV24V
24
V DC

SD-3

GD-3

Gas
Sensor10 / 17Signal output(4-20mA)(4– 20 mA)

2-3 Safety accuracy
Safety accuracy: 20 %*The FMEDA failure rate includes failures of internal parts causing deviations exceeding thisaccuracy.
Applicable sensors:

NCF series

Gas response:

50 % of response time is within 20 seconds
90 % of response time is within 60 seconds

Applicable sensors:

IRF series

Gas response:

50 % of response time is within 20 seconds
90 % of response time is within 60 seconds

2

Applicable sensors:

ESF(Toxic) series

Gas response:

50 % of response time is within 60 seconds
90 % of response time is within 150 seconds

5

Applicable sensors:

ESF(O2) series

Gas response:

20 % of response time is within 10 seconds
90 % of response time is within 45 seconds

2-4 Diagnosis response
ROM/RAM check self-diagnostic: 24 hours
Maximum response time for self-diagnostic results other than the above: 20 seconds

3*This indicates that notification is output within this time with regard to part failures detectedby the self-diagnostic.s. Note that this is the combined total time for the self-diagnostic test
interval and failure response time.
2-5 Setup
Refer to ‘5.Usage Instruction’ in the “SD-3 Series Export Specifications Technical Manualfor SIL and FM Specifications (PT2E-287) rev.7”. Also test the parameters already set.
9
2-6 Proof test
Proof test details:

Calibration, adjustment of 4 - 20 mA output values, sensor
replacement, etc.
11 / 174

Do not replace the sensor by yourself.
(Refer to ‘7-7-2 Replacement of periodic replacement parts’ in the“SD-3Series Export Specifications Technical Manual for SIL and FM
Specifications (PT2E-287) rev.7” for the frequency for replacing
Proof test standards:

sensors.) 9
Must allow/perform calibration.
Alarm delay times and gas response times must meet performance
expectations.

MTTR:

24 hours

Tools used:

Refer below

Tools used

Specifications

MaintenanceCalibration gas

Depends on gas type.

Must be traceable.

Calibration

Dedicated calibration adapter for IRF sensors

Undamaged

adapter(4283 9011 00)
Dedicated calibration adapter for combustible F
sensors (4283 9012 70)
2 Dedicated calibration adapter for ESF sensors(4283 9013 40)

Pump
Flowmeter

One with flow rate of 0.5 L/min or more

Maintenance by the

One meeting explosion-proof specifications

manufacturer

One capable of measuring to 0.1 L tolerances

Maintenance by the

One with markings allowing identification of flow

manufacturer

rate settings and tolerances
It is also possible to adjust the flow rate with apump equipped with a flowmeter
Piping

For general combustible gases –Material: PolyurethaneInternal diameter: 4 mm
Pipe length: Within 1 m
For organic solvent gases –Material: Teflon
Internal diameter: 4 mm
Pipe length: Within 1 m
For strongly adsorptive gases –Material: Teflon
Internal diameter: 4 mm
Pipe length: Within 10 cm
12 / 17

Undamaged

Proof test procedure
1) Bypass the safety function and take appropriate action to avoid a false trip.
2) Use HART communications to retrieve any diagnostuics and take appropriate action.
3) Send a HART command to the gas detector to go to the high alarm current output andverify that the analog current reaches that value.*1
4) Send a HART command to the gas detector to go to the low alarm current output andverify that the analog current reaches that value.*25) Inspect the gas detector for any leaks, visible damage, or contamination.
6) Perform a two-point calibration of the gas detector over the full working range.
7) Remove the bypass and otherwise restore normal operation*1

This tests for compliance voltage problems such as a low loop power supply voltage orincreased wiring resistance. This also tests for other possible failures.
*2This tests for possible quiescent current related failures.

* Functionality anticipates disabling of product functions when performing the proof test.
* Keep a record of proof test results.
(Refer to the “SD-3 Series Export Specifications Technical Manual for SIL and FM
9*This product may malfunction if the proof test is not performed correctly. The proof test
Specifications (PT2E-287) rev.7” for more information.)must be performed by trained service personnel.
2-7 Maintenance
For maintenance items other than the proof test, refer to ‘7. Maintenance’ in the “SD-3
Series Export Specifications Technical Manual for SIL and FM Specifications (PT2E-287)
rev.7”. 9
2-8 Repairs and replacements
Refer to ‘7-7 Parts replacement’ in the “SD-3 Series Export Specifications Technical Manualfor SIL and FM Specifications (PT2E-287) rev.7”. 9
2-9 Storage, Relocation, and Disposal
Refer to ‘8. Storage, Relocation, and Disposal’ in the “SD-3 Series Export Specifications
Technical Manual for SIL and FM Specifications (PT2E-287) rev.7”.

92-10 Startup time (initialization time)
Refer to ‘5.Usage Instruction’ in the “SD-3 Series Export Specifications Technical Manual for
SIL and FM Specifications (PT2E-287) rev.7”. 9

13 / 17

2-11 Reliability data
Failure rates, failure modes, and other information are recorded in the following FMEDA
report.
<H/W Version 2.1 or earlier>
5

Model

FMEDA report Report No.:

SD-3EC

RK 21/04-192 R003 V3R3

4

5

7

<H/W Version 2.2 or later> 9
Model

FMEDA report Report No.:

SD-3RI

RK 19/01-130 R001 V3R5

SD-3NCRK 20/05-036 R002 V2R5

SD-3EC

RK 21/04-192 R003 V3R4

SD-3ECB

RK 22/05-277 R004 V1R5

Refer to the separate ‘FMEDA Report’.
To satisfy SIL2, use at HFT = 0. To satisfy SIL3, use at HFT = 1.
2-12 Operation modeLow frequency operation request mode (frequency of operation requests is once annually or
less)
2-13 Availability rate
Availability rate: Constantly available
2-14 Power source
Rating: 24 V DC
Allowable range: 18.0 to 30.0 V DC
2-15 Product service life
Product service life: 10 years (Othen than the sensor).
3

3 years (sensor)

The reliability data in the FMEDA report is valid only during this period.
2-16 Requested parameter settings• The 4 - 20 mA output value in the event of a use involving burnout (failure) is 3.6 mA or lessor 21 mA or greater.
• From a security perspective, use a write protect function that prevents changes in settings
via HART protocol signals.
14 / 17• The above requirements must be met for applications involving functional safety.
2-17 Limitations on installation and operating environments
Installation: Refer to ‘4. Installation’ in the “SD-3 Series Export Specifications Technical
Manual for SIL and FM Specifications (PT2E-287) rev.7”. 9
Operating environment: Refer to ‘10. Product Specifications’ in the “SD-3 Series Export
Specifications Technical Manual for SIL and FM Specifications (PT2E-287) rev.7”.

92-18 Application limitations
Refer to ‘5.Usage Instruction’ in the “SD-3 Series Export Specifications Technical Manual for
SIL and FM Specifications (PT2E-287) rev.7”. 9
2-19 Identification of hardware/software configurations
12

SD-3EC(H2S):

9

Software Version

Ver 2.1

Hardware Version

Ver 2.1

6
6

8
8

6
6

8
8

SD-3RI
SD-3NC
SD-3EC(H2S,CO,O2)
SD-3ECB(CL2,NH3,NO2)
Software Version

Ver 2.2

Hardware Version

Ver 2.2

2-20 Product Specifications
Refer to ‘10. Product Specifications’ in the “SD-3 Series Export Specifications Technical
Manual for SIL and FM Specifications (PT2E-287) rev.7”.

92-21 Error codes and message
Corrective action and procedures when faults or errors occur
Refer to ‘9.Troubleshooting’ in the “SD-3 Series Export Specifications Technical Manual for
SIL and FM Specifications (PT2E-287) rev.7”. 9
2-22 Operator interfaces
Refer to ‘5.Usage Instruction’ in the “SD-3 Series Export Specifications Technical Manual for
SIL and FM Specifications (PT2E-287) rev.7”. 9

15 / 17

2-23 Prohibited items
Modification of this product is prohibited.
2-24 Terminology and abbreviations
Term
SafetyFreedom from unacceptable risk of harm.

Functional Safety

The ability of a system to carry out the actions necessary to achieve
or to maintain a defined safe state for the equipment under control ofsystemBasic Safety

The equipment must be designed and manufactured such that it
protects against resulting fire and explosion under explosive
atmosphere

Safety Assessment

The investigation to arrive at a judgment - based onevidence - of the safety achieved by safety-related systems

Fail-Safe State

State that the defined fail-safe

Fail Safe

Failure that go to the defined fail-safe state without a demand fromthe process

Fail Dangerous

Failure that does not respond to a demand from the process(i.e. being unable to go to the defined fail-safe state).
Failure that deviates the process signal or the actual output by morethan 15% of span, drifts away from the user defined threshold (Trip
Point) and that leaves the output within active scale.

Fail Dangerous

Failure that is dangerous and that is not being diagnosed byUndetected

automatic stroke testing.

Fail Dangerous

Failure that is dangerous but is detected by automatic stroke testing.

Detected
Fail Annunciation

Failure that does not cause a false trip or prevent the safety function

Undetectedbut does cause loss of an automatic diagnostic and is not detectedby another diagnostic.

Fail Annunciation

Failure that does not cause a false trip or prevent the safety function

Detected

but does cause loss of an automatic diagnostic or false diagnostic
indication.

Fail No EffectFailure of a component that is part of the safety function but that has
no effect on the safety function.

Low demand mode

Mode, where the frequency of demands for operation made on asafety-related system is no greater than twice the proof test
frequency.

16 / 17

Abbreviations
FMEDA

Failure Modes, Effects and Diagnostic Analysis

HFT

Hardware Fault Tolerance
Tolerance that to keep executing the function requested under the
hardware fault and error condition

MOC

Management of ChangeManagement of change the hardware or software elements, andkeep traceability

PFDavgAverage Probability of Failure on Demand

SFF

Safe Failure Fraction
The fraction of the overall failure rate of a device that results in eithera safe fault or a diagnosed unsafe fault.

SIF

Safety Instrumented Function
A set of equipment intended to reduce the risk due to a specifichazard.

SIL

Safety Integrity Level
Discrete level (one out of a possible four) for specifying the safety
integrity requirements of the safety functions to be allocated to the
E/E/PE safety-related systems where Safety Integrity Level 4 has thehighest level of safety integrity and Safety Integrity Level 1 has thelowest.

SIS

Safety Instrumented System
Implementation of one or more Safety
Instrumented Functions. A SIS is composed of any combination of
sensor(s), logic solver(s), and final element(s).

17 / 17