Pepperl+Fuchs HiC283 Series User manual

ISO9001
2
Functional Safety
Switch Amplifier HiC283*
Manual

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: [phone] - 0
E-mail: [e-mail]
North American Headquarters
Pepperl+Fuchs Inc.
1600 Enterprise Parkway
Twinsburg, Ohio 44087
USA
Phone: [phone]
E-mail: [email protected].com
Asia Headquarters
Pepperl+Fuchs Pte. Ltd.
P+F Building
18 Ayer Rajah Crescent
Singapore 139942
Phone: [phone]
E-mail: [email protected]
https://www.pepperl-fuchs.com

3
Functional Safety HiC283*
Contents
2021-12
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Standards and Directives for Functional Safety . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Useful Lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Mounting and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 Proof Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Functional Safety HiC283*
Contents
4
2021-12

Functional Safety HiC283*
Introduction
2021-12
5
1 Introduction
1.1 Content of this Document
This document contains information for usage of the device in functional safety-related
applications. 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
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 examination certificate
•EU declaration of conformity
•Attestation of conformity
•Certificates
•Control drawings
•FMEDA report
•Assessment report
•Additional documents
For more information about Pepperl+Fuchs products with functional safety,
see www.pepperl-fuchs.com/sil.
Note
This document does not substitute the instruction manual.
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 HiC283*
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.

Functional Safety HiC283*
Introduction
2021-12
7
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.
Depending on the risk level, the warning messages are displayed in descending order
as follows:
Informative Symbols
Action
This symbol indicates a paragraph with instructions. You are prompted to perform an action
or a sequence of actions.
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.
Note
This symbol brings important information to your attention.

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Functional Safety HiC283*
Product Description
2 Product Description
2.1 Function
General
This isolated barrier is used for intrinsic safety applications.
The device transfers digital signals from NAMUR sensors or dry contacts from the hazardous
area to the non-hazardous area.
Via switches the mode of operation can be reversed and the line fault detection
can be switched off.
This device mounts on a HiC termination board.
HiC2831 and HiC2832
The input controls two passive transistor outputs with a resistive output characteristic
(acc. to EN60947-5-6).
The outputs have three defined states: low impedance state: 1-signal = 1.8 k,
high impedance state: 0-signal = 14 k and fault > 100 k.
This output characteristic offers line fault transparency on the signal lines.
HiC2831R1 and HiC2832R1
The input controls two passive transistor outputs with a resistive output characteristic.
The outputs have three defined states: 1-signal = 6.5 V voltage drop,
high impedance state: 0-signal = 33 k and 6.5 V voltage drop and fault > 100 k.
This output characteristic offers line fault transparency on the signal lines.
HiC2831R2 and HiC2832R2
The input controls two passive transistor outputs with a resistive output characteristic.
The outputs have three defined states: low impedance state: 1-signal = 5 k,
high impedance state: 0-signal = 15 k and fault > 100 k.
This output characteristic offers line fault transparency on the signal lines.
HiC2831R3 and HiC2832R3
The input controls two passive transistor outputs with a resistive output characteristic.
The outputs have three defined states: low impedance state: 1-signal = 100 to 600 ,
high impedance state: 0-signal = 19 k and fault > 100 k.
This output characteristic offers line fault transparency on the signal lines.
HiC2831R4 and HiC2832R4
The input controls two passive transistor outputs with a resistive output characteristic.
The outputs have three defined states: low impedance state: 1-signal = 472 ,
high impedance state: 0-signal = 1.4 k and fault > 100 k.
This output characteristic offers line fault transparency on the signal lines.
HiC2831R5 and HiC2832R5
The input controls two passive transistor outputs with a resistive output characteristic.
The outputs have three defined states: low impedance state: 1-signal = 8.8 k,
high impedance state: 0-signal = 45.5 k and fault > 100 k.
This output characteristic offers line fault transparency on the signal lines.

Functional Safety HiC283*
Product Description
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9
2.2 Interfaces
The device has the following interfaces:
•Safety relevant interfaces:
•1-channel devices: input I, output I, output II (optional)
•2-channel devices: input I, input II, output I, output II
•Non-safety relevant interfaces: power supply, fault output
2.3 Marking
2.4 Standards and Directives for Functional Safety
Device-specific standards and directives
System-specific standards and directives
Note
For corresponding connections see datasheet.
Pepperl+Fuchs Group
Lilienthalstraße 200, 68307 Mannheim, Germany
Internet: www.pepperl-fuchs.com
HiC2831, HiC2832, HiC2831R1, HiC2832R1
HiC2831R2, HiC2832R2, HiC2831R3, HiC2832R3
HiC2831R4, HiC2832R4, HiC2831R5, HiC2832R5
Up to SIL 2
Note
If you design the safety loops in homogeneous redundancy (HFT = 1), you can use the devices
in applications up to SIL 3.
Functional safety IEC/EN 61508, part 2, edition 2010:
Functional safety of electrical/electronic/programmable electronic
safety-related systems (manufacturer)
Functional safety IEC 61511-1:2016+COR1:2016+A1:2017
EN 61511-1:2017+A1:2017
Functional safety –Safety instrumented systems for the process
industry sector (user)

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Functional Safety HiC283*
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 PFDavg value (average Probability of dangerous Failure on Demand)
and the T1 value (proof test interval that has a direct impact on the PFDavg value)
•the SFF value (Safe Failure Fraction)
•the HFT architecture (Hardware Fault Tolerance)
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 = (s + dd) / (s + dd + du)
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 the elements and subsystems, but not of a single device.
Nevertheless the SFF of the device is given in this document for reference.

Functional Safety HiC283*
Planning
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3.2 Assumptions
The following assumptions have been made during the FMEDA:
•Failure rate based on the Siemens standard SN 29500.
•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.
•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.
•Do not use more than one input channel of a multi-channel device for a safety loop,
as the channels of the device use common components. Observe that a multi-channel
device contains components that affect the behavior of all channels.
SIL 2 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 2 application operating in low demand mode the total PFDavg value
of the SIF (Safety Instrumented Function) should be smaller than 10-2,
hence the maximum allowable PFDavg value would then be 10-3.
•For a SIL 2 application operating in high demand mode the total PFH value
of the SIF should be smaller than 10-6 per hour, hence the maximum allowable PFH value
would then be 10-7 per hour.
•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.

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Functional Safety HiC283*
Planning
3.3 Safety Function and Safe State
Safe State
The safe state of output I and output II is the high impedance state or the fault state.
Safety Function
HiC2831*
HiC2832*
Switch Position Function
Output I and output II
S1 II Normal mode of
operation
If a low current is present at input I,
output I and output II are high impedant
(safe state).
S1 I Inverse mode of
operation
If a high current is present at input I,
output I and output II are high impedant
(safe state).
Table 3.1 Switch settings HiC2831*
Switch Position Function
Channel I
S1 II Normal mode of
operation
If a low current is present at input I,
output I is high impedant (safe state).
S1 I Inverse mode of
operation
If a high current is present at input I,
output I is high impedant (safe state).
Channel II
S3 II Normal mode of
operation
If a low current is present at input II,
output II is high impedant (safe state).
S3 I Inverse mode of
operation
If a high current is present at input II,
output II is high impedant (safe state).
Table 3.2 Switch settings HiC2832*

Functional Safety HiC283*
Planning
2021-12
13
Line Fault Diagnostics
If the line fault detection is enabled (mandatory, see datasheet), the input circuit is monitored
in all device versions. If a line fault is detected, the outputs change in the fault state (safe state).
Reaction Time
•The response time for the safety function between input and output is < 0.1 ms.
Load conditions:
•HiC283*: 8 V, 1 k
•HiC283*R1: 24 V, 2 k
•HiC283*R2: 24 V, 250 
•HiC283*R3: 24 V, 4.2 k
•HiC283*R4: 10 mA current source
•HiC283*R5: 24V, 200 to 250 
•The fault detect and fault reaction time is < 100 ms. A fault diagnostics at the input leads
to fault state
Note
The fault indication output is not safety relevant.
Note
See corresponding datasheets for further information.

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Functional Safety HiC283*
Planning
3.4 Characteristic Safety Values
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).
Parameters Characteristic values
Assessment type and
documentation
Full assessment
Device type A
Mode of operation Low demand mode, high demand mode or continuous mode
HFT 0
SIL 2
SC 3
MTBF 1 (HiC2831*)
1acc. to SN29500. This value includes failures which are not part of the safety function/MTTR = 24 h.
154 years
MTBF 1 (HiC2832*) 120 years
PTC 99 %
Safety function Inverse mode of operation 2
2The device can be used in two modes of operation, inverse of mode operation and normal mode of operation.
Normal mode of operation 2
safe 106 FIT 106 FIT
dd 3.3 FIT 3.3 FIT
du 26.8 FIT 22.8 FIT
total (safety function) 136 FIT 132 FIT
SFF 3
3"Annunciation failures" and "No effect failures" are not influencing the safety function and are therefor not included in the calculation
of the SFF.
80 % 82 %
PFH 2.68 x 10-8 1/h 2.28 x 10-8 1/h
PFDavg for T1 = 1 year 1.28 x 10-4 1.09 x 10-4
PFDavg for T1 = 2 years 2.56 x 10-4 2.18 x 10-4
PFDavg for T1 = 5 years 6.40 x 10-4 5.44 x 10-4
Fault reaction time 4
4The combined fault detection and fault reaction time is the time in which the device reacts to an occurred fault.
< 100 ms
Table 3.3

Functional Safety HiC283*
Planning
2021-12
15
3.5 Useful Lifetime
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, 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.
Please note that the useful lifetime refers to the (constant) failure rate of the device.
The effective life time can be higher.
The estimated useful lifetime is greater than the warranty period prescribed by law
or the manufacturer's guarantee period. However, this does not result in an extension
of the warranty or guarantee services. Failure to reach the estimated useful lifetime
is not a material defect.

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Functional Safety HiC283*
Mounting and Installation
4 Mounting and Installation
Mounting and 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
Configuring the Device
The device is configured via DIP switches. The DIP switches for setting the safety functions
are on the side of the device.
1. De-energize the device before configuring the device.
2. Remove the device.
3. Configure the device for the required safety function via the DIP switches, see chapter 3.3.
4. Secure the DIP switches to prevent unintentional adjustments.
5. Mount the device.
6. Connect the device again.
Note
See corresponding datasheets for further information.

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Operation
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5 Operation
Operating the device
1. Observe the safety instruction 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 24 hours. Take measures to maintain
the safety function while the device is being repaired.
5.1 Proof Test Procedure
This section describes a possible proof test procedure. The user is not obliged to use
this proposal. The user may consider different concepts with an individual determination
of the respective effectiveness, e. g. concepts according to NA106:2018.
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 PFDavg
in accordance with the characteristic safety values. 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.
Check the settings after the configuration by suitable tests.
Equipment required:
•Digital multimeter with an accuracy of 0.1 %
Use for the proof test of the intrinsic safety side of the device a special digital multimeter
for intrinsically safe circuits.
If intrinsically safe circuits are operated with non-intrinsically safe circuits,
they must no longer be used as intrinsically safe circuits.
•For R4 version: current source 10.0 mA ±1 %
•For all other versions: dual power supply, set to 24 V DC resp. 8 V DC (NAMUR voltage).
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 HiC283*
Operation
Proof Test Procedure
1. Prepare a test set-up, see figures below.
2. Test the devices in the mode of operation they are used in. If necessary,
change the configuration of the device. Verify the input and output values as given
in table below.
3. Test each input channel individually.
4. Simulate the sensor state by a potentiometer of 4.7 k. The threshold must be between
1.4 mA and 1.9 mA. The hysteresis must be between 150 A and 250 A.
For normal mode of operation the outputs must have a low impedance, if the input current
is above the threshold. This state is indicated by yellow LED.
For inverse mode of operation the outputs must have a low impedance, if the input current
is below the threshold. This state is indicated by yellow LED.
5. Simulate the sensor state by a resistor RSC (220 , short circuit detection) or a resistor RLB
(150 k, lead breakage detection).
The device must detect an external fault. This state is indicated by red LED and the output
of the corresponding channel must be in fault state.
6. Test the outputs with a certain current. Test that the outputs are definitely high impedant
(see table, Ioff), if the yellow LED is off.
7. Set back the device to the original settings after the test.
8. Secure the DIP switches to prevent unintentional adjustments.
Device R U Ion (mA) Ioff (mA) Ifault (mA)
HiC283* 1 k8 V 2.6 mA < Ion < 3.2 mA 0.5 mA < Ioff < 0.6 mA Ifault < 0.05 mA
HiC283*R1 2 k24 V 8.0 mA < Ion < 9.2 mA 0.46 mA < Ioff < 0.62 mA Ifault < 0.05 mA
HiC283*R2 250 24 V 4.2 mA < Ion < 4.6 mA 1.48 mA < Ioff < 1.62 mA Ifault < 0.05 mA
HiC283*R3 4.3 k24 V 4.9 mA < Ion < 5.2 mA 1.01 mA < Ioff < 1.06 mA Ifault < 0.05 mA
HiC283*R5 250 24 V 2.54 mA < Ion < 2.76 mA 0.5 mA < Ioff < 0.55 mA Ifault < 0.05 mA
Table 5.1 Input and output values for HiC28*1, HiC283R2, HiC283*R3 and HiC283*R5
Device I Uon (V) Uoff (V) Ifault (mA)
HiC283*R4 10.0 mA 4.58 V < Uon < 4.85 V 13.3 V < Uoff < 14.35 V Ifault < 0.05 mA
Table 5.2 Input and output values for HiC283*R4

Functional Safety HiC283*
Operation
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Figure 5.1 Proof test set-up for HiC2831R1
Figure 5.2 Proof test set-up for HiC2832R1
Termination Board
Zone 0, 1, 2
Div. 1, 2
Zone 2
Div. 2
Multimeter
( I)
Multimeter
( I) R
U
Multimeter
( I)
R
U
Fault
10a
9a
12
15
5a
5b
1
4
+
-
+
-
SL2 8a
SL1
7a
11
14
+
-
Supply +
Supply -
24 V DC
Power
supply
I supply
Supply
Bus
RLB RSC
Termination Board
Zone 0, 1, 2
Div. 1, 2
Zone 2
Div. 2
Multimeter
( I)
Multimeter
( I) R
U
Multimeter
( I)
R
U
Fault
10a
9a
12
15
5a
5b
1
4
+
-
+
-
SL2
Multimeter
( I)
1a
1b
2
5
+
-
8a
SL1
7a
11
14
+
-
Supply +
Supply -
24 V DC
Power
supply
I supply
Supply
Bus
RLB RSC
RLB RSC

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Functional Safety HiC283*
Operation
Figure 5.3 Proof test set-up for HiC2831, HiC2831R2, HiC2831R3, and HiC2831R5
Figure 5.4 Proof test set-up for HiC2832, HiC2832R2, HiC2832R3, and HiC2832R5
Termination Board
Zone 0, 1, 2
Div. 1, 2
Zone 2
Div. 2
Multimeter
( I)
Multimeter
( I) R
U
Multimeter
( I)
R
U
Fault
10a
9a
12
15
5a
5b
1
4
+
-
+
-
SL2 8a
SL1
7a
11
14
+
-
Supply +
Supply -
24 V DC
Power
supply
I supply
Supply
Bus
RLB RSC
Termination Board
Zone 0, 1, 2
Div. 1, 2
Zone 2
Div. 2
Multimeter
( I)
Multimeter
( I) R
U
Multimeter
( I)
R
U
Fault
10a
9a
12
15
5a
5b
1
4
+
-
+
-
SL2
Multimeter
( I)
1a
1b
2
5
+
-
8a
SL1
7a
11
14
+
-
Supply +
Supply -
24 V DC
Power
supply
I supply
Supply
Bus
RLB RSC
RLB RSC