Pepperl+Fuchs HiC2027 Series User manual

ISO9001
2
3
Functional Safety
SMART Transmitter Power
Supply HiC2027**, 
KCD2-STC-(Ex)1.2O.**
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 HiC2027**, KCD2-STC-(Ex)1.2O.**

Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Content
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1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Symbols Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Useful Life Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Proof Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 21
7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Functional Safety Manual HiD2872, HiC2873(Y1), HiD2876, HiC2877

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Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Introduction
1Introduction
1.1 Contents
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:
•Presentdocument
• Instruction manual
•Manual
• Datasheet
Additionally, the following parts may belong to the documentation, if applicable:
• EC-type of examination
• EU declaration of conformity
• Attestation of conformity
• Certificates
• Control drawings
• FMEDA report
• Assessment report
• Additional documents
For more information about functional safety products from Pepperl+Fuchs 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 KFD2-SR3-(Ex)2.2S

Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
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.
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.

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Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Introduction
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 HiC2027**, KCD2-STC-(Ex)1.2O.**
Product Description
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2 Product Description
2.1 Function
General
The device supplies 2-wire transmitters in the hazardous area, and can also be
used with current sources.
It transfers the analog input signal to the safe area as two isolated output signals.
Bi-directional communication is supported for SMART transmitters that use
current modulation and voltage modulation for the information transfer.
The output is selected as a current source, current sink, or voltage source via
switches.
HiC2027**
This isolated barrier is used for intrinsic safety applications.
This device mounts on a HiC Termination Board.
KCD2-STC-1.2O
This signal conditioner provides the galvanic isolation between field circuits and
control circuits.
Test sockets for the connection of HART communicators are integrated into the
terminals of the device.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
KCD2-STC-Ex1.2O.**
This isolated barrier is used for intrinsic safety applications.
Test sockets for the connection of HART communicators are integrated into the
terminals of the device.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
2.2 Interfaces
The device has the following interfaces.
• Safety relevant interfaces: input I, output I, output II
• Non-safety relevant interfaces: none
The HART communication is not relevant for functional safety.
Note!
For corresponding connections see datasheet.
Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**

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Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Product Description
2.3 Marking
2.4 Standards and Directives for Functional Safety
Device specific standards and directives
System-specific standards and directives
Pepperl+Fuchs GmbH
Lilienthalstraße 200, 68307 Mannheim, Germany
Internet: www.pepperl-fuchs.com
HiC2027, HiC2027DE,
KCD2-STC-1.2O, KCD2-STC-Ex1.2O,
KCD2-STC-Ex1.2O.DE
Up to SIL 2
HiC2027ES, KCD2-STC-Ex1.2O.ES Up to SIL 3
Functional safety IEC/EN 61508, part 1 –7, 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)

Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
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 T1value (proof test interval that has a direct impact on the PFDavg value)
• the SFF value (Safe Failure Fraction)
•theHFTarchitecture(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)
•theHFTarchitecture(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.
Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**

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Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
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.
• External power supply failure rates are not included.
• 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, which
are comparable with the classification "stationary mounted" in MIL-HDBK-
217F. Alternatively, the following ambient conditions are assumed:
• IEC/EN 60654-1 Class C (sheltered location) with temperature limits in the
range of the manufacturer's specifications and an average temperature of
40 ºC over a long period. The humidity level is within manufacturer's rating.
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.
• Any safe failures that occur (e. g. output in safe state) will be corrected within
24 hours (e. g. remove sensor fault).
• While the device is being repaired, measures must be taken to maintain the
safety function (e. g. substitution by a replacement device).
• The HART function is only used for configuration, calibration and diagnostics,
not during operation.
• The application program in the programmable logic controller (PLC) is
configured to detect underrange and overrange 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.
• Since the safety loop has a hardware fault tolerance of 0and 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.

Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Planning
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SIL 3 application
• 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 0and 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.
3.3 Safety Function and Safe State
Safe State
Ensure that the emergency shutdown (ESD) reacts adequately when the outputs
are
• < 4 mA or > 20 mA,
• < 1 V or > 5 V.
Safety Function
The device transfers analog signals from the input to the output with a deviation of
less than 2 %.
The outputs of the device must be configured by DIP switches. All valid
configurations are allowed for use within safety functions.
Note!
All operating modes that can be set on the device are permitted in the safety
function.
Operating mode of the
output
Input signals Output signals
Current sink, current
source
0/4 mA to 20 mA 0/4 mA to 20 mA
Voltage source 0/4 mA to 20 mA 0/1 V to 5 V
Table 3.1

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Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Planning
KCD2-STC-(Ex)1.2O.** devices
HiC2027(ES) devices
Operating mode Switch S1 Switch S2
Current source output III
Current sink output II II
Voltage source output I I
Not valid II I
Table 3.2 Switch settings output I
Operating mode Switch S3 Switch S4
Current source output II I
Current sink output II II
Voltage source output I I
Not valid III
Table 3.3 Switch settings output II
Operating mode Switch S1 Switch S2
Current source output I I
Current sink output III
Voltage source output II I
Not valid II II
Table 3.4 Switch settings output I
Operating mode Switch S3 Switch S4
Current source output I I
Current sink output III
Voltage source output II I
Not valid II II
Table 3.5 Switch settings output II

Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Planning
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HiC2027DE device
Reaction Time
The reaction time for all safety functions is < 50 ms.
Operating mode Switch S3 Switch S4
Current source output I I
Current sink output III
Voltage source output II I
Not valid II II
Table 3.6 Switch settings output I
Operating mode Switch S5 Switch S6
Current source output I I
Current sink output III
Voltage source output II I
Not valid II II
Table 3.7 Switch settings output II
Note!
For more information see the corresponding datasheets.

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Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Planning
3.4 Characteristic Safety Values
SIL 2 Versions: HiC2027(DE), KCD2-STC-(Ex)1.2O(.DE)
Parameters acc. to IEC 61508 Characteristic values
Assessment type and documentation Full assessment
Device type A
Operating mode Low Demand Mode or High Demand Mode
HFT 0
SIL (SC) 2
Safety function Transfer of analog signals
s1
1"No effect failures" and "Annunciation failures" are not influencing the safety function and are therefore not
included in SFF and in the failure rates of the safety function.
0 FIT
dd 222 FIT
du 55 FIT
annunciation 0 FIT
total (safety function) 277 FIT
total (one channel) 920 FIT
SFF 180 %
PTC 100 %
MTBF 2
2acc. to SN29500. This value includes failures which are not part of the safety function/MTTR = 24 h. The
value is valid for one channel only.
124 years
PFH 5.49 x 10-8 1/h
PFDavg for T1= 1 year 2.40 x 10-4
PFDavg for T1= 2 years 4.81 x 10-4
PFDavg for T1= 5 years 1.20 x 10-3
Reaction time < 50 ms
Table 3.8

Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Planning
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SIL 3 Versions: HiC2027ES, KCD2-STC-Ex1.2O.ES
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 acc. to IEC 61508 Characteristic values
Assessment type and
documentation
Full assessment
Device type A
Operating mode Low Demand Mode or High Demand Mode
HFT 0
SIL (SC) 3
Safety function Transfer of analog signals
Input and output function Channel 1 Channel 2
s1
1"No effect failures" and "Annunciation failures" are not influencing the safety function and are therefore not
included in SFF and in the failure rates of the safety function.
0 FIT 0 FIT
dd 229 FIT 243 FIT
du 7.0 FIT 8.4 FIT
annunciation 26.2 FIT 26.2 FIT
total (safety function) 236 FIT 251 FIT
total (one channel) 953 FIT 951 FIT
SFF 197.0 % 96.6 %
PTC 100 % 100 %
MTBF 2
2acc. to SN29500. This value includes failures which are not part of the safety function/MTTR = 24 h. The
value is valid for one channel only.
120 years 120 years
PFH 7.00 x 10-9 1/h 8.37 x 10-9 1/h
PFDavg for T1= 1 year 3.06 x 10-5 3.67 x 10-5
PFDavg for T1= 2 years 6.13 x 10-5 7.33 x 10-5
PFDavg for T1= 5 years 1.53 x 10-4 1.83 x 10-4
Reaction time < 50 ms < 50 ms
Table 3.9

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Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Planning
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.

Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Mounting and Installation
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4 Mounting and Installation
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!
For more information see the corresponding datasheets.
Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**

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Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Operation
5Operation
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
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.
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
• Process calibrator with current source and current sink function with an
accuracy better than 20 µA
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 HiC2027**, KCD2-STC-(Ex)1.2O.**

Functional Safety HiC2027**, KCD2-STC-(Ex)1.2O.**
Operation
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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. Test the devices. Verify the current values as given in table below.
4. Set back the device to the original settings for the application after the test.
Figure 5.1 Proof test set-up for HiC2027**
Step
No.
Input value (mA) Configuration
Current source/current sink
(mA)
Voltage source (V)
120.0 20.0 ±0.4 5.0 ±0.1
212.0 12.0 ±0.4 3.0 ±0.1
34.0 4.0 ±0.4 1.0 ±0.1
423.0 23.0 ±0.4 5.75 ±0.1
5 0 < 0.2 < 0.1
Table 5.1 Steps to be performed for the proof test
HiC2027
+
-
+
-10a
9a
SL1
8a
7a
1a
1b
SL2
5a
5b
1a, 1b
2a, 2b
-
+
Termination Board
2
5
1
4
12
15
11
14
Zone 2
Div. 2
Zone 0, 1, 2
Div. 1, 2
I
II
-
+
-
+
Multimeter
(mA/V)
Multimeter
(mA/V)
Signal calibration
4 mA to 20 mA
I
supply
24 V DC
Power
supply
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 HiC2027**, KCD2-STC-(Ex)1.2O.**
Operation
Figure 5.2 Proof test set-up for KCD2-STC-(Ex)1.2O.**
Usage in Zone 0, 1, 2/Div. 1, 2 only for KCD2-STC-Ex1.2O, 
KCD2-STC-Ex1.2O.DE, KCD2-STC-Ex1.2O.ES
KCD2-STC-Ex1.2O
1+
2-
3+
4-
Zone 2
Div. 2
Zone 0, 1, 2
Div. 1, 2
5
6
I
7
8
-
+
-
+
II
Multimeter
(mA/V)
Multimeter
(mA/V)
9+
10-
Signal calibration
4 mA to 20 mA
24 V DC
Power
supply
I
supply