Pepperl+Fuchs KCD2-SR Series User manual

ISO9001
2
Functional Safety
Switch Amplifier
KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
PROCESS AUTOMATION
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"
Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*

Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Content
2018-12
3
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Content of this Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Symbols Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Standards and Directives for Functional Safety . . . . . . . . . . . . . . . . . 10
3 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 System Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Safety Function and Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Characteristic Safety Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Useful Life Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Proof Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2018-12
4
Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Introduction
1Introduction
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.

Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Introduction
2018-12
5
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.

2018-12
6
Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Introduction
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.

Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Product Description
2018-12
7
2 Product Description
2.1 Function
KCD2-SR-1.LB(.SP)
This signal conditioner provides the galvanic isolation between field circuits and control
circuits. The device transfers digital signals (NAMUR sensors or dry contacts) from the field
to the control system.
The proximity sensor or the mechanical contact controls the normally open relay output
for the control side load. The device output changes the state when the input signal changes
the state.
Via switches the mode of operation can be reversed and the line fault detection
can be switched off.
Via switch the function of the second output can be defined as a signal output or a fault
indication output.
During an error condition, the relay reverts to its de-energized state and the LEDs indicate
the fault according to NAMUR NE44.
If the device is operated via Power Rail, additionally a collective error message is available.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
SP version
The devices are available with screw terminals or spring terminals. The type code
of the versions of the devices with spring terminals has the extension ".SP".
KCD2-SR-Ex1.LB(.SP)
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.
The device transfers digital signals (NAMUR sensors or dry contacts) from the field
to the control system.
The proximity sensor or the mechanical contact controls the normally open relay output
for the control side load. The device output changes the state when the input signal changes
the state.
Via switches the mode of operation can be reversed and the line fault detection
can be switched off.
Via switch the function of the second output can be defined as a signal output or a fault
indication output.
During an error condition, the relay reverts to its de-energized state and the LEDs indicate
the fault according to NAMUR NE44.
If the device is operated via Power Rail, additionally a collective error message is available.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
SP version
The devices are available with screw terminals or spring terminals. The type code
of the versions of the devices with spring terminals has the extension ".SP".

2018-12
8
Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Product Description
KCD2-SR-2(.SP)
This signal conditioner provides the galvanic isolation between field circuits and control
circuits. The device transfers digital signals (NAMUR sensors or dry contacts) from the field
to the control system.
The proximity sensor or the mechanical contact controls the normally open relay output
for the control side load. The device output changes the state when the input signal changes
the state.
Via switches the mode of operation can be reversed and the line fault detection
can be switched off.
During an error condition, the relay reverts to its de-energized state and the LEDs indicate
the fault according to NAMUR NE44.
If the device is operated via Power Rail, additionally a collective error message is available.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
SP version
The devices are available with screw terminals or spring terminals. The type code
of the versions of the devices with spring terminals has the extension ".SP".
KCD2-SR-Ex2(.SP)
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.
The device transfers digital signals (NAMUR sensors or dry contacts) from the field
to the control system.
The proximity sensor or the mechanical contact controls the normally open relay output
for the control side load. The device output changes the state when the input signal changes
the state.
Via switches the mode of operation can be reversed and the line fault detection
can be switched off.
During an error condition, the relay reverts to its de-energized state and the LEDs indicate
the fault according to NAMUR NE44.
If the device is operated via Power Rail, additionally a collective error message is available.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
SP version
The devices are available with screw terminals or spring terminals. The type code
of the versions of the devices with spring terminals has the extension ".SP".

Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Product Description
2018-12
9
HiC2821
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.
The proximity sensor or the mechanical contact controls the normally open relay output
for the control side load. The device output changes the state when the input signal changes
the state.
Via switches the mode of operation can be reversed and the line fault detection
can be switched off.
Via switch the function of the second output can be defined as a signal output or a fault
indication output.
During an error condition, the relay reverts to the de-energized state and LEDs indicate
the fault according to NAMUR NE44. A separate output bus is available.The fault conditions
are monitored via a Fault Indication Board.
This device mounts on a HiC termination board.
HiC2822
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.
The proximity sensor or the mechanical contact controls the normally open relay output
for the control side load. The device output changes the state when the input signal changes
the state.
Via switches the mode of operation can be reversed and the line fault detection
can be switched off.
During an error condition, the relay reverts to the de-energized state and LEDs indicate
the fault according to NAMUR NE44. A separate output bus is available.The fault conditions
are monitored via a Fault Indication Board.
This device mounts on a HiC termination board.

2018-12
10
Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Product Description
2.2 Interfaces
The device has the following interfaces.
• Safety relevant interfaces:
KCD2-SR-(Ex)1.LB(.SP), HiC2821: input I, output I, output II
KCD2-SR-(Ex)2(.SP), HiC2822: input I, input II, output I, output II
• Non-safety relevant interfaces: 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 GmbH
Lilienthalstraße 200, 68307 Mannheim, Germany
Internet: www.pepperl-fuchs.com
KCD2-SR-1.LB(.SP), KCD2-SR-Ex1.LB(.SP)
KCD2-SR-2(.SP), KCD2-SR-Ex2(.SP)
HiC2821, HiC2822
Up to SIL 2
Functional safety IEC/EN 61508, part 1 –2, edition 2010:
Functional safety of electrical/electronic/programmable electronic
safety-related systems (manufacturer)
Functional safety IEC/EN 61511, part 1, edition 2003:
Functional safety –Safety instrumented systems for the process
industry sector (user)

Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Planning
2018-12
11
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:
•thePFD
avg value (average Probability of dangerous Failure on Demand) and
the T1value (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:
•thePFHvalue(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 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.

2018-12
12
Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Planning
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.
• Only one input and one output are part of the safety function (only for 2-channel version).
• The safety-related device is considered to be of type Adevice 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 indication of a dangerous failure (via fault bus) is detected within 1 hour
by the programmable logic controller (PLC).
SIL 2 Application
• The device shall claim less than 10 % of the total failure budget for a SIL 2 safety loop.
• 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 0and it is a type Adevice,
the SFF must be > 60 % according to table 2 of IEC/EN 61508-2 for a SIL 2 (sub) system.
3.3 Safety Function and Safe State
Safe State
The safe state is the de-energized state of the outputs, independent of the mode of operation.
Safety Function
The safety function has 2 modes of operation:
• normal operation (output follows input)
• inverted operation (output inverts input)
The 1-channel devices have 2 outputs where output II may be used in safety-relevant
applications if output II is configured to follow output I.
Use the following DIP switch settings for safety-related applications:

Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Planning
2018-12
13
DIP Switch Settings 1-channel Devices
DIP Switch Settings 2-channel Devices
LB/SC Diagnosis
The input loops of all versions are supervised, if the line fault detection is active (mandatory,
see datasheet). The related safety function is defined as the outputs are in fault state
(safe state), if there is a line fault detected.
Reaction Time
The reaction time for all safety functions is < 20 ms.
Function Mode KCD2-SR-(Ex)1.LB(.SP) HiC2821
Mode of operation
output I
normal mode S1 position I S1 position II
inverted mode S1 position II S1 position I
Assignment output II follow output I S2 position I S3 position I
LB/SC detection 1
1This switch setting may not be used if output II is used for safety-relevant applications.
S2 position II S3 position II
Line fault detection ON S3 position I S2 position I
OFF 2
2This switch setting may not be used if the device is used for safety-relevant applications.
S3 position II S2 position II
Table 3.1
Function Mode KCD2-SR-(Ex)2(.SP) HiC2822
Mode of operation
channel 1
normal mode S1 position I S1 position II
inverted mode S1 position II S1 position I
Mode of operation
channel 2
normal mode S2 position I S3 position II
inverted mode S2 position II S3 position I
Line fault detection
channel 1
ON S3 position I S2 position I
OFF 1
1This switch setting may not be used if the channel is used for safety-relevant applications.
S3 position II S2 position II
Line fault detection
channel 2
ON S4 position I S4 position I
OFF 1S4 position II S4 position II
Table 3.2
Note!
The fault indication output is not safety relevant.
Note!
See corresponding datasheets for further information.

2018-12
14
Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Planning
3.4 Characteristic Safety Values
The characteristic safety values like PFD, SFF, HFT and T1are taken
from the SIL report/FMEDA report. Observe that PFD and T1are 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 or High Demand Mode
HFT 0
SIL (SC) 2
Safety function 1 relay output for 1 channel 2 relay outputs for a
1-channel device
s99 FIT 126 FIT
dd 18.2 FIT 47.5 FIT
du 40.3 FIT 11.1 FIT
total (safety function)1
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.
158 FIT 184 FIT
not part 58 FIT 58 FIT
SFF 174.5 % 93.99 %
PTC 100 % 100 %
MTBF 2
2acc. 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.
366 years 310 years
PFH 4.03 x 10-8 1/h 1.11 x 10-8 1/h
PFDavg for Tproof = 1 year 1.93 x 10-4 5.34 x 10-5
PFDavg for Tproof = 2 years 3.85 x 10-4 1.06 x 10-4
PFDavg for Tproof = 5 years 5.77 x 10-4 1.59 x 10-4
Reaction time 3
3Time between fault detection and fault reaction
< 20 ms
Table 3.3

Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Planning
2018-12
15
3.5 Useful Life Time
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, the 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.
Our experience has shown that the useful lifetime of a Pepperl+Fuchs product can be
higher if the ambient conditions support a long life time, for example if the ambient temperature
is significantly below 60 °C.
Please note that the useful lifetime refers to the (constant) failure rate of the device.
The effective life time can be higher.

2018-12
16
Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Planning
Maximum Switching Power of Output Contacts
The useful life time is limited by the maximum number of switching cycles under load
conditions. The maximum number of switching cycles is depending on the electrical load
and may be higher when reduced currents and voltages are applied.
You can see the relationship between the maximum switching power and the load conditions
in the figures below.
Figure 3.1 Maximum switching power of HiC282*
Figure 3.2 Maximum switching power of KCD2-SR-(Ex)*(.LB)(.SP)
1
I (A)
10050 U (V) 30
0.5
0.3
Resistive load DC
Electrical life
max. 1 x 10
5
switching cycles
Electrical life
max. 2.5 x 10
5
switching cycles
1
I (A)
2
4
40
10030 50 200
115 253
U (V)
20
Electrical life
max. 1 x 10
5
switching cycles
0.5
0.4
0.15
Resistive load DC Resistive load AC
Note!
See corresponding datasheets for further information.

Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Mounting and Installation
2018-12
17
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 Devices with DIP Switches on the Device Side
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.
Configuring the Devices with DIP Switches on the Front Side
The device is configured via DIP switches. The DIP switches for setting the safety functions
are on the front of the device.
1. De-energize the device before configuring the device.
2. Open the cover.
3. Configure the device for the required safety function via the DIP switches, see chapter 3.3.
4. Close the cover.
5. Secure the DIP switches to prevent unintentional adjustments.
6. Connect the device again.
Note!
See corresponding datasheets for further information.

2018-12
18
Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Operation
5Operation
Operating the device
1. Observe the safety instructions 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 8 hours. Take measures to maintain the
safety function while the device is being repaired.
5.1 Proof Test
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.
Equipment required:
• Digital multimeter with an accuracy better than 0.1 %
Use for the proof test of the intrinsic safety side of the device a special digital multimeter
for intrinsically safe circuits.
Intrinsically safe circuits that were operated with non-intrinsically safe circuits may
not be used as intrinsically safe circuits afterwards.
• Power supply set to nominal voltage of 24 V DC
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.

Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Operation
2018-12
19
Proof Test Procedure
1. Put out of service the entire safety loop. Protect the application by means of other measures.
2. Prepare a test set-up, see figures below.
3. Simulate the sensor state by connecting a potentiometer, a resistor for short circuit
detection or by a resistor for lead breakage detection.
Test each input channel individually.
4. Connect a potentiometer of 4.7 k(threshold for normal operation) to the input.
The threshold must be between 1.4 mA and 1.9 mA, the hysteresis must
be between 170 µA and 250 µA.
- If the input current is above the threshold the relay must be activated for
normal mode of operation. The yellow LED lights up.
- If the input current is below the threshold the relay must be activated for
inverted mode of operation. The yellow LED lights up.
5. Connect a resistor RSC of 220 or a resistor RLB of 150 kto the input.
The device detects an external fault. The relay of the corresponding channel
must be de-activated. The red LED flashes.
6. Test both relay outputs with a specific current, e. g. 100 mA. To avoid electric shock,
use a test voltage of 24 V DC. Check that the relay contacts are open.
The relays must be de-activated. The relay contacts must definitely open.
7. Set back the device to the original settings for the application after the test.
8. Check the correct behavior of the safety loop. Is the configuration correct?
9. Secure the DIP switches to prevent unintentional adjustments.
Figure 5.1 Proof test set-up for KCD2-SR-(Ex)1.LB(.SP)
Usage in Zone 0, 1, 2/Div. 1, 2 only for KCD2-SR-Ex1.LB(.SP).
KCD2-SR-Ex1.LB
Zone 2
Div. 2
Zone 0, 1, 2
Div. 1, 2
Multimeter
(mA)
5
6
1+
2-
7
8
Multimeter
(mA)
Multimeter
(mA)
240 Ω/2.5 W
24 V DC
Multimeter
(mA)
240 Ω/2.5 W
24 V DC
9+
10-
I
II
24 V DC
Power
supply
I supply
RLB RSC

2018-12
20
Functional Safety KCD2-SR-(Ex)*(.LB)(.SP), HiC282*
Operation
Figure 5.2 Proof test set-up for KCD2-SR-(Ex)2(.SP)
Usage in Zone 0, 1, 2/Div. 1, 2 only for KCD2-SR-Ex2(.SP).
Figure 5.3 Proof test set-up for HiC2821, HiC2822
Channel 2 only for HiC2822.
Zone 2
Div. 2
Zone 0, 1, 2
Div. 1, 2
Multimeter
(mA)
5
6
1+
2-
7
8
KCD2-SR-Ex2
Multimeter
(mA)
3+
4-
Multimeter
(mA)
Multimeter
(mA)
240 Ω/2.5 W
24 V DC
Multimeter
(mA)
240 Ω/2.5 W
24 V DC
9+
10-
I
II
24 V DC
Power
supply
I
supply
R
LB
R
SC
R
LB
R
SC
Termination Board
HiC2822
Zone 2
Div. 2
Zone 0, 1, 2
Div. 1, 2
I
II
10a
9a
SL1
8a
7a
12
15
11
14
1a, 1b
2a, 2b
5a
5b
1
4
-
+
+
SL2
1a
1b
2
5
+
-
-
Multimeter
( mA )
Multimeter
( mA )
Multimeter
(mA)
240 Ω/2.5 W
24 V DC
Multimeter
( mA)
240 Ω/2.5 W
24 V DC
Multimeter
(mA)
I
supply
24 V DC
Power
supply
RLB RSC
RLB RSC
Tip
The easiest way to test HiC devices is by using a stand-alone HiCTB**-SCT-***-**-**
termination board. In this test, it is not necessary to disconnect the wiring of the existing
application. Faults in a subsequent wiring can be avoided.