Pepperl+Fuchs HiD2872 User manual

ISO9001
2
3
Functional Safety
Solenoid Driver
HiD2872, HiC2873(Y1),
HiD2876, HiC2877
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 HiD2872, HiC2873(Y1), HiD2876, HiC2877

Functional Safety HiD2872, HiC2873(Y1), HiD2876, HiC2877
Content
2019-07
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Useful Lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 Proof Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Functional Safety HiD2872, HiC2873(Y1), HiD2876, HiC2877
Introduction
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.

Functional Safety HiD2872, HiC2873(Y1), HiD2876, HiC2877
Introduction
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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.

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Functional Safety HiD2872, HiC2873(Y1), HiD2876, HiC2877
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 HiD2872, HiC2873(Y1), HiD2876, HiC2877
Product Description
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2 Product Description
2.1 Function
General
This isolated barrier is used for intrinsic safety applications.
The device supplies power to solenoids, LEDs and audible alarms located in
a hazardous area.
The output signal has a resistive characteristic. As a result the output voltage and current
are dependent on the load.
Line fault detection of the field circuit is indicated by a red LED and an output on the fault bus.
HiD2872
This device is a 2-channel device.
The device is loop powered or bus powered.
It is controlled with a loop powered control signal, switch contact, transistor, or logic signal.
At full load, 12 V at 40 mA (with 55 mA current limit) is available for the hazardous
area application.
An alternative low current output is available for driving a single LED without installing
an external current limiting resistor.
This device mounts on a HiD Termination Board.
HiC2873
This device is a 1-channel device.
The device is loop powered or bus powered.
It is controlled with a loop powered control signal, switch contact, transistor, or logic signal.
At full load, 12 V at 40 mA (with 55 mA current limit) is available for the hazardous
area application.
This device mounts on a HiC termination board.

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Functional Safety HiD2872, HiC2873(Y1), HiD2876, HiC2877
Product Description
HiC2873Y1
This device is a 1-channel device.
The device is bus powered.
The device is controlled with a switch contact, transistor, or logic signal.
At full load, 12 V at 40 mA (with 55 mA current limit) is available for the hazardous
area application.
This device mounts on a HiC termination board.
HiD2876
This device is a 2-channel device.
The device is loop powered or bus powered.
It is controlled with a loop powered control signal, switch contact, transistor, or logic signal.
At full load, 11.2 V at 40 mA (with 55 mA current limit) is available for the hazardous
area application.
An alternative low current output is available for driving a single LED without installing
an external current limiting resistor.
This device mounts on a HiD Termination Board.
HiC2877
This device is a 1-channel device.
The device is loop powered or bus powered.
It is controlled with a loop powered control signal, switch contact, transistor, or logic signal.
At full load, 11.2 V at 40 mA (with 55 mA current limit) is available for the hazardous
area application.
This device mounts on a HiC termination board.

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Product Description
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2.2 Interfaces
The device has the following interfaces.
• Safety relevant interfaces:
• HiC2873(Y1), HiC2877: input I, output I
• HiD2872, HiD2876: 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 GmbH
Lilienthalstraße 200, 68307 Mannheim, Germany
Internet: www.pepperl-fuchs.com
HiD2872
HiC2873
HiD2876
HiC2877
Up to SIL 2 (bus powered)
Up to SIL 3 (loop powered)
HiC2873Y1 Up to SIL 2 (bus powered)
Functional safety IEC/EN 61508, part 2, edition 2010:
Functional safety of electrical/electronic/programmable
electronic safety-related systems (manufacturer)
Functional safety IEC/EN 61511, part 1 –3, edition 2003:
Functional safety – Safety instrumented systems for the
process industry sector (user)

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Functional Safety HiD2872, HiC2873(Y1), HiD2876, HiC2877
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 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.

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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.
• 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.
• Failure rates are constant, wear is not considered.
• External power supply failure rates are not included.
• Since the outputs of the device use common components, these outputs must not be used
in the same safety function.
SIL 2 application (bus powered)
• A SIL 2 application can also be implemented in bus powered mode.
For corresponding connections see datasheet.
• 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 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.
SIL 3 application (loop powered)
• SIL 3 is not available for HiC2873Y1.
• A SIL 3 application can only be implemented using the loop powered mode.
For corresponding connections see datasheet.
• The device shall claim less than 10 % of the total failure rate for a SIL 3 safety loop.
• For a SIL 3 application operating in low demand mode the total PFDavg value of the
SIF (Safety Instrumented Function) should be smaller than 10-3, hence the maximum
allowable PFDavg value would then be 10-4.
• For a SIL 3 application operating in high demand mode the total PFH value of
the SIF should be smaller than 10-7 per hour, hence the maximum allowable PFH value
would then be 10-8 per hour.
• Since the safety loop has a hardware fault tolerance of 0 and it is a type A device,
the SFF must be > 90 % according to table 2 of IEC/EN 61508-2 for a SIL 3 (sub) system.

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Planning
3.3 Safety Function and Safe State
Safe State
The safe state of the output is the de-energized state. The output current is less than 0.4 mA.
Safety Function
The output is de-energized if the input is in low state. The low state is reached when the input
voltage is 5 V or below or the contact is open.
DIP switch settings
The device is configured by DIP switches.
The filter (switch S6) and the line fault detection (switch S5) are not safety relevant. However,
use of the line fault detection feature is recommended for safety applications. Consider the
consequences if the device remains in the safe state.
Reaction Time
The combined fault detection and fault reaction time is the time in which the device reacts
to an occurred fault.
The reaction time (switch off delay) for the safety function is < 100 ms.
Note!
See corresponding datasheets for further information.

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Planning
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3.4 Characteristic Safety Values
SIL 3 Application (Loop Powered)
Parameters Characteristic values
Assessment type FMEDA report
Device type A
Mode of operation Low demand mode, high demand mode or continuous mode
Safety function De-energized if the input is in low condition
HFT 0
SIL 3
SC 3
s127 FIT
dd 0 FIT
du 0 FIT
total (safety function) 127 FIT
no effect 131 FIT
SFF 100 %
MTBF 1
1acc. to SN29500. This value includes failures which are not part of the safety function/MTTR = 24 h.
The value is calculated for one safety function of the device.
293 years
PFH 2
2As the d failure rate is 0 FIT, a PFD calculation yields a PFD of zero, independent from the proof test interval.
0 1/h
PFDavg for T1= 1 year 20
T1 max. 2Defined in "Proof Test" chapter but not necessary to validate
the safety values, see chapter 5.1.
PTC 100 %
Reaction time 3
3Time between fault occurence and fault reaction
< 100 ms
Table 3.1

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Planning
SIL 2 Application (Bus Powered)
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 FMEDA report
Device type A
Mode of operation Low demand mode, high demand mode or continuous mode
Safety function De-energized if the input is in low condition
HFT 0
SIL 2
SC 3
s97 FIT
dd 0 FIT
du 30 FIT
total (safety function) 127 FIT
no effect 131 FIT
SFF 76 %
MTBF 1
1acc. to SN29500. This value includes failures which are not part of the safety function/MTTR = 24 h.
The value is calculated for one safety function of the device.
293 years
PFH 2.96 x 10-8 1/h
PFDavg for T1 = 1 year 1.41 x 10-4
PFDavg for T1 = 2 years 2.70 x 10-4
PFDavg for T1 = 5 years 6.55 x 10-4
PTC 99 %
Reaction time 2
2Time between fault occurence and fault reaction
< 100 ms
Table 3.2

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Planning
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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, 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.

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Functional Safety HiD2872, HiC2873(Y1), HiD2876, HiC2877
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
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.
When the device is used in loop powered mode no dangerous failures can occur.
A proof test is not necessary. Nevertheless, we recommend a regular functional test of
the device, e. g. in combination with the proof test of the final element.
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 HiD2872, HiC2873(Y1), HiD2876, HiC2877
Operation
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.
• Power supply set to nominal voltage of 24 V DC
• Load resistor according to table
Check the settings after the configuration by suitable tests.
Proof Test Procedure
1. Connect load and supply as shown in the figures on the following pages.
2. Measure the output voltage via multimeter. Compare the value to the nominal value
specified in the table below.
3. Short circuit the load resistor and measure the short circuit current via multimeter.
Compare the resulting value to the nominal value specified in the table below.
4. Set the input voltage to 5 V.
The output current must stay below 0.4 mA. This is the safety function:
when the input is in low condition the output must definitely be de-energized.
5. If applicable, repeat the test procedure for output II by connecting the power supply
between the appropriate terminals. Repeat the output voltage and short circuit test.
6. Restore the safety loop. Remove any by-passes from the safety loop.
Device Output resistor () Output voltage (V) Short circuit current (mA)
HiD2872, HiC2873,
HiC2873Y1
300 > 12 50 < Isc < 60
HiD2876, HiC2877 280 > 11.2 50 < Isc < 60
Table 5.1 Expected test results for the proof test

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Operation
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Figure 5.1 Proof test set-up for 1-channel devices (example HiC2877)
Figure 5.2 Proof test set-up for 1-channel device HiC2873Y1
Termination Board
1
4
11
14
12
15
HiC2877
Zone 0, 1, 2
Div. 1, 2
Multimeter
(mA)
Multimeter
(V)
R
load
SC
24 V DC
FAULT
1a, 1b
2a, 2b
6b
-
+
V
SL2
5a
5b
SL1
8a
7a
10a
9a
+
-
+
-
+
-
Termination Board
1
4
11
14
HiC2873Y1
Zone 0, 1, 2
Div. 1, 2
Multimeter
(mA)
Multimeter
(V)
R
load
SC
24 V DC
FAULT
1a, 1b
2a, 2b
6b
-
+
V
SL2
5a
5b
SL1
8a
7a
+
-
+
-
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.

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Functional Safety HiD2872, HiC2873(Y1), HiD2876, HiC2877
Operation
Figure 5.3 Proof test set-up for 2-channel devices (example HiD2876)
Termination Board
HiD2876
Zone 0, 1, 2
Div. 1, 2
Multimeter
(mA)
Multimeter
(V)
R
load
SC
Multimeter
(mA)
Multimeter
(V)
R
load
SC
+
-
+
-
+
-
+
-
SL2
7a
5a
5b
SL1
8a
7a
8b
7b
3b
1a
1b
10a
9a
9b
10b
24 V DC
FAULT
1a, 1b
2a, 2b
6b
11
14
1
5
2
4
12
15
13
16
7
+
-
+
+
-
+6
17
18
-
+
I
II
V
V
Tip
The easiest way to test HiD devices by using a stand-alone HiDTB**-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.