PT2E-2320

Smart transmitter/Gas Detector HeadSD-1(TYPE GP S)
Safety Manual(320-13141TE)
Project Number：77AG265ZZ0[Note] SD-1GP is a SIL2 product based on the IEC 61508 standard. Installation, operation or
maintenance of this product must be performed according to this safety manual to obtain compliance withthe functional safety standard. If not, the safety integrity will be degraded.

Revision/Abolition History
RevDetails

0

Newly created.

1

Completely revised

2

Clerical error correction

3

Revised by TIIS witness indication.

4Reliability data modification by
FMEDA changeApproved by

Checked by

Created by

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

January 16, 2014

January 16, 2014

January 16, 2014

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

January 24, 2014

January 24, 2014

January 24, 2014

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

January 29, 2014

January 29, 2014

January 29, 2014

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

February 14, 2014

February 14, 2014

February 14, 2014

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

April 8, 2014

April 8, 2014

April 8, 2014

Masaru Ishibashi

Takuo Aida

Ryoji HayashiApril 17, 2014

April 17, 2014

April 17, 2014

5

Clerical error correction

6

Reliability data modification by
FMEDA change

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

May 19, 2014

May 19, 2014

May 19, 2014

Reliability data modification by

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

May 21, 2014

May 21, 2014

May 21, 2014

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

May 23, 2014

May 23, 2014

May 23, 2014

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

July 15, 2014

July 15, 2014

July 15, 2014

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

August 20, 2014

August 20, 2014

August 20, 2014

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

October 16, 2014

October 16, 2014

October 16, 2014

Masaru Ishibashi

Takuo Aida

Ryoji Hayashi

December 11, 2014

December 11, 2014

December 11, 2014

78

FMEDA change
Reliability data modification byFMEDA change

9

Revised by Sira audit.

10

Revised by Sira audit.

11

Clerical error correction

12

Fit to certificate

Contents
1. Purpose ..................................................................................................................................................4
2. Safety Policy...........................................................................................................................................4
3. Scope .....................................................................................................................................................5
4. Safety Specifications ..............................................................................................................................54-1. Safety function .................................................................................................................................54-2. Safety integrity .................................................................................................................................54-3. Reliability data .................................................................................................................................54-4. Safety accuracy ...............................................................................................................................64-5. Diagnostic response time ................................................................................................................64-6. Gas detection times .........................................................................................................................64-7. Fault conditions ...............................................................................................................................64-8. Lifetime limits ...................................................................................................................................64-9. Environmental limits.........................................................................................................................74-10. Application limits ............................................................................................................................74-11. Hardware/Software configuration ...................................................................................................7
5. Using This Detector ................................................................................................................................85-1. Installation .......................................................................................................................................85-2. Configuration and calibration ...........................................................................................................85-3. Proof testing ....................................................................................................................................95-4. Daily Check .....................................................................................................................................95-5. Routine maintenance .......................................................................................................................95-6. Repair and replacement ................................................................................................................105-7. Modification ...................................................................................................................................105-8. Disposal .........................................................................................................................................10
6. Terms and Definitions ...........................................................................................................................10

Safety Manual

1. Purpose
This safety manual provides the following requirements for which the user has responsibility for the caseSD-1 (TYPE GP S) (hereinafter referred to as "the device") is used as a part of safety instrumentedfunction. Read this safety manual and all the related documents to use the device safely.
 Proof testing Repair and replacement
 Reliability data
 Lifetime limits
 Environmental and application limits
 Setting parameters

2. Safety Policy“Creating safe working environments for workers “RIKEN KEIKI has set this as unswerving business policy since 1939.
“Workers” to whom RIKEN KEIKI wishes to supply “Security and safety” include not only customers using
our products, but also all employees and vendors who are related to our production stream.
“Work with a sense of security” leads to a perception of ”Work with a sense of safety”.
Therefore, RIKEN KEIKI believes that supplying continuously wide-ranging products which can provide“Safety” with workers who work in various environments results in realizing “safe working environments”.
For the realization, the functional safety based on IEC 61508 is materialized by this product, and RIKEN
KEIKI promises that we are in compliance with the following items.
a) Functional safety management responsible person on this product is appointed, who is ultimately
responsible for activities of all E/E/PE system safety lifecycles.
b)

In full compliance with documented planning and procedure, perform development, production,maintenance, customization and disposal in accordance with quality management system to realize
the E/E/PE system safety lifecycle.

c)

The personnel who evaluate works and output of each phase of all E/E/PE system safety lifecycle arerequired to have enough level of ability for each phase, and “Education on Functional safety” isprovided and “Evaluation on level of ability” is performed periodically.

d) Validation on the product is performed by personnel who belong to an independent department in
RIKEN KEIKI and have enough level of ability. In addition, perform an overall assessment of works
on each phase and output to achieve functional safety with being inspected by external institution whois not interested party.
4

3. ScopeThis safety manual is applied to the following IEC 61508: 2010 Part 2 SIL 2 capable certified model.
･ SD-1 (TYPE GP S)

4. Safety Specifications
4-1. Safety function
The element safety function of the product is defined as follows:
To provide the host system signal information of the combustible gas concentration of the LEL set-point
using 4-20mA and relay contact outputs.
Note: the LEL set-point is adjustable to 10% - 60%.
Output currents ＜ 3.6mA and > 21mA are reserved for revealed failures.
Output currents ≧ 3.6mA and ≦ 21mA are reserved for normal conditions
4-2. Safety integrity
Safety integrity: IEC 61508:

2010 Part 2 SIL 2 capable

Operation mode : Low demand mode
HFT (Hardware Fault Tolerance)
Type:0: Type B

4-3. Reliability data
Information about failure rate and failure mode etc. is written in FMEDA repot. Contact RIKEN KEIKI for
the details of FMEDA report.
Table 1 : Failure rates according to IEC 61508 SD-1 (TYPE GP S)

λSD

λSU

λDD

λDU

SFF

284 FIT341 FIT

200 FIT83.3 FIT

91%-4PFD avg: 1.89 x 10

<Applicable condition>
Proof testing interval:

6 months

MTTR: 48 hours

54-4. Safety accuracy
Safety accuracy: 10%* A failure of internal part that produces an error above this value is included in FMEDA failure rate.
4-5. Diagnostic response time
Maximum response time of self-diagnosis: 15 seconds* A notice of a part failure detected by self-diagnosis is given within this time period. This time period is asum of the self-diagnostic test interval and failure response time.
4-6. Gas detection times
50% response time: Within 10 seconds
90% response time: Within 30 secondsThese are the times required for the LED display or 4 to 20 mA output to indicate 50% or 90% of a
combustible gas concentration after the gas makes contact with the device.
When the gas concentration reaches or exceeds an alarm point, it takes an extra time (alarm delaytime) to confirm the alarming concentration internally before the contact output is activated.
4-7. Fault conditions
The device is put into the following conditions when a problem is detected by the self-diagnostic function.
 An error message is displayed on LED.
 The 4 to 20 mA output becomes lower than 3.6 mA or higher than 21 mA, and the failure contact is
activated for the case [Fault alarm] or [Gas alarm or fault alarm] is selected for the alarm contact
specification.
* Connect the 4 to 20 mA output or contact output to the host system. This is necessary to notify that aproblem has occurred and put the functional safety system into safe state.
Measure against failure Check the detail of failure and take a countermeasure within the recovery time of functional safetysystem.
* Refer to the operation manual for other measures.
4-8. Lifetime limits
Product life: 10 years from manufacturing date
 The reliability data of FMEDA report is valid within this period.
 When this period has passed, the failure rate may increase.
 When this period has passed, SIL 2 will not be satisfied.

6

4-9. Environmental limits
Avoid the following environments to install the device. The reliability data of FMEDA report becomes
invalid if the device is installed in such environments.
 Place with shock or vibration
 Place exposed to water, oil, chemical, etc.
 Place exposed to direct sunlight or rapid temperature change Place with a noise source (which may affect the main unit or cable)
 Place where maintenance cannot be performed or any danger may be caused during maintenancework Place without appropriate grounding work Place where the operating temperature/humidity range is exceeded
Operating temperature range: -20 to +60℃ (overseas specification), -20 to +53℃ (Japanesespecification)
Operating humidity range: 95%RH or lower (no condensation)
Storage temperature humidity range: -20 to +60℃, 95%RH or lower (no condensation)
 Place where a gas with interference or poisoning effect is not present
Exposure to poisonous substances (silicone, halogen compound, sulfur compound, etc.) causes thesensitivity of catalytic combustion sensor to be degraded. The device cannot be used in suchenvironment.
 Place without oxygen
The device cannot measure a combustible gas without oxygen due to its detection principle.
 Place where a combustible gas with high concentration is present
If the device detects a combustible gas with high concentration which exceeds the lower explosion
limit (100%LEL), accurate measurement may not be performed due to lack of oxygen. It may also
cause disconnection of the sensor.
4-10. Application limits Rated power voltage/allowable range: 24 VDC/17.0 to 26.4 VDC
 Power consumption: 3 W at maximum
 4 to 20 mA output load resistance: 300 Ω or lower
 Contact output load capacity: 250 VAC･0.5 A / 30 VDC･0.5 A or lower
4-11. Hardware/Software configuration
Hardware identification number：Part list
Terminal PCB：PLT-2905-1904-90（Rev.0）
Main PCB：PLT-2905-1905-60（Rev.0）
Circuit schematic
Terminal PCB：E3-2905-1904-90-01N（Rev.0）
Main PCB：E3-2905-1905-60-01N（Rev.0）7

Software identification number：
・Program drawing number：E4-2975-0173-40-01Z（Rev.0）

5. Using This Detector
5-1. Installation
Refer to the operation manual.
5-2. Configuration and calibration
The correct operation must be performed for gas calibration after installation.
Refer to the operation manual for the gas calibration procedure.
After installation, check that the following items use the default settings. When you have requested a
special setting, check that the setting is done correctly.
Refer to the operation manual for how to check the settings.
ItemAlarm point

Default
25%LEL

Settable range

Alarm contact specification

Normallyenergized
2 seconds
Valuecorresponding
to indication
Gas alarm
4 mA

Normally energized/de-energized

Gas alarm delay
Analog output during alarm test

Contact output specification
Analog output during
maintenance mode

10 to 60％LEL

2 to 60 seconds
Value corresponding to indication/4 mA

Gas alarm/failure/gas alarm or failure contact
2.5 mA/4 mA/fixed to a value just before entering
maintenance mode/a value corresponding toindication8

5-3. Proof testing
Carry out proof testing when routine maintenance (every 6 month) is performed.
Proof testing procedure
1)

Bypass the safety function or take an appropriate measure to prevent malfunction of the host system
as needed.
Note: During proof testing, the 4 to 20 mA output signal to the host system may be disabled in order tocheck the 4 to 20 mA output value.

2)

Perform routine maintenance (Zero adjustment and span adjustment)

3)

Check gas response time (T50 and T90) with span gases introduced.
Measure the 4 to 20 mA output value while performing a gas test with zero and span gasesintroduced.
Check the contact output as well when it is used.
Check the 4 to 20 mA output value while performing a gas test with zero and span gases introduced.
Check the contact output as well when it is used.
*The 4 to 20 mA output becomes 4 mA with zero gas introduced, whereas it becomes a value
corresponding to gas concentration with span gas introduced.
*Check that the contact output operation is performed according to the setting.
* If an alarm point is higher than the span gas concentration, lower the setpoint temporarily.

4)

Stop introducing span gas and wait for the indication to return.

5)

Return the alarm point to the original value if it was changed in the step 3).

6)

Restore the condition before performing the step 1).

* Only the trained service personnel should be allowed to perform proof testing since an erroneous
operation can cause malfunction of the device.
* The combustible gas concentration measurement function is stopped during proof testing; therefore,take an appropriate measure to ensure EUC safety.
* Replace a sensor when calibration is unable to be done.
5-4. Daily Check
Refer to the operation manual for the details of daily check.
1）Check frequency
Check before work2）Check item
Check the indication3）Check content
Check that the indicated value is zero. If the indicated value is not zero, perform zero adjustment
after no interference gases exist around the environment.
5-5. Routine maintenance
Refer to the operation manual for the details of routine maintenance.
1)

Periodic calibration
9At least once every six months
2)

Periodic sensor replacement
The sensor parts have lifetime limits. It is required to replace the parts before the limits for correct
operation.
Replace a sensor when calibration is unable to be done
Even if the calibration history shows a good result, replace the sensor every three years. The sensor
cannot be used for more than this period.

3)

Periodic cleaning
Remove any visible dirt, etc. from the sintered metal.
The frequency of cleaning depends on the diagnostic result.
*Only the trained service personnel should be allowed to perform routine maintenance since anerroneous operation can cause malfunction of the device.
*The combustible gas concentration measurement function is stopped during routine maintenance;
therefore, take an appropriate measure to ensure EUC safety.

5-6. Repair and replacement
Repair and replacement of degraded parts are performed by the service company specified by RIKEN
KEIKI with the user's agreement.
5-7. Modification
The default setting has been performed on the device prior to shipment. Changing the setting is password
protected. Please do not change the settings on the user side. If the setting needs to be changed, Pleasecontact the service company of our specification or our sales office.
5-8. Disposal
Refer to the operation manual for how to dispose of the device.

6. Terms and Definitions
Terms
Alarm point
Combustible gas
Lower explosion
limit
EUC

Description
A threshold which can be set arbitrarily within the range of 10 to 60% of
the concentration of lower explosion limit.
Methane, isobutane, hydrogen, etc.
A minimum value of concentration which can trigger explosion of target
combustible gas
Controlled equipment, plant, etc.

End of document10