Pepperl+Fuchs KCD2-UT2-1 User manual

ISO9001
2
Functional Safety
Temperature Converter
KCD2-UT2-(Ex)1, HiC2081
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-UT2-(Ex)1, HiC2081

Functional Safety KCD2-UT2-(Ex)1, HiC2081
Content
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Standards and Directives for Functional Safety . . . . . . . . . . . . . . . . . . 8
3 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 System Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Safety Function and Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Characteristic Safety Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Useful Life Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Proof Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Proof Test Procedure for KCD2-UT2-(Ex)1 . . . . . . . . . . . . . . . . . . . . . 15
5.3 Proof Test Procedure for HiC2081 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Functional Safety KCD2-UT2-(Ex)1, HiC2081
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.

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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 KCD2-UT2-(Ex)1, HiC2081
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.

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Product Description
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2 Product Description
2.1 Function
KCD2-UT2-1
This signal conditioner provides the galvanic isolation between field circuits and control
circuits.
The device converts RTD input signals or thermocouple input signals on the field side to
0/4 mA ... 20mA signals on the control side.
The removable terminal block KC-CJC-** is available for thermocouples when internal cold
junction compensation is desired.
A fault is indicated by an LED and by user-configured fault indication outputs.
If the device is operated via Power Rail, additionally a collective error message is available.
The device is easily configured by the use of the PACTware configuration software.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
KCD2-UT2-Ex1
This isolated barrier is used for intrinsic safety applications.
The device converts RTD input signals or thermocouple input signals in the hazardous area to
0/4 mA ... 20mA signals in the safe area.
The removable terminal block KC-CJC-** is available for thermocouples when internal cold
junction compensation is desired.
A fault is indicated by an LED and by user-configured fault indication outputs.
If the device is operated via Power Rail, additionally a collective error message is available.
The device is easily configured by the use of the PACTware configuration software.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
HiC2081
This isolated barrier is used for intrinsic safety applications.
This device accepts thermocouples (TC), millivolts, potentiometers, or resistance temperature
detectors (RTD) from a hazardous area and converts them to an isolated, linearized analog
output in the safe area.
The output can be selected as a current source or current sink with a switch.
Line fault detection of the field circuit is indicated by a red LED and an output on the fault bus.
The fault conditions are monitored via a Fault Indication Board.
The device is easily configured by the use of the PACTware configuration software.
This device mounts on a HiC Termination Board.

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Functional Safety KCD2-UT2-(Ex)1, HiC2081
Product Description
2.2 Interfaces
The device has the following interfaces.
• Safety relevant interfaces: input, output
• Non-safety relevant interfaces: programming socket, collective error message 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-UT2-1, KCD2-UT2-Ex1, HiC2081 Up to SIL 2
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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Planning
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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 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:
•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.

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Functional Safety KCD2-UT2-(Ex)1, HiC2081
Planning
3.2 Assumptions
The following assumptions have been made during the FMEDA:
• Failure rate based on the Siemens standard SN29500.
• Failure rates are constant, wear is not considered.
• Failures during configuration are not considered.
• The collective error message output is not considered in the FMEDA and in the
calculations.
• Propagation of failures is not relevant.
• External power supply failure rates are not included.
• The collective error message output is not safety relevant.
• The indication of a dangerous failure (via fault bus) is detected within 1 hour by the
programmable logic controller (PLC).
• The safety-related device is considered to be of type Bdevice 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 application program in the programmable logic controller (PLC) is configured to detect
underrange and overrange failures. These failures have been classified as dangerous
detected failures.
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.
• The IEC/EN 61511-1 section 11.4.4 allows devices to be used in applications one SIL
higher than given by table 3 of IEC/EN 61508-2, if the device is proven-in-use. The
assessment and proven-in-use demonstration lead to the result that the device may be
used in applications up to SIL 2. However, it is the responsibility of the end-user to decide
on applying proven-in-use devices.