Pepperl+Fuchs SIL KCD2-STC-1.HC User guide

ISO9001
2
SMART Transmitter
Power Supply
KCD2-STC-(Ex)1.HC(.SP),
HiC2025HC
PROCESS AUTOMATION
SAFETY MANUAL SIL

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"
Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC

Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Contents
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1 Introduction......................................................................... 4
1.1 General Information .......................................................................................4
1.2 Intended Use ................................................................................................4
1.3 Manufacturer Information ..............................................................................5
1.4 Relevant Standards and Directives ...............................................................5
2 Planning .............................................................................. 6
2.1 System Structure...........................................................................................6
2.1.1 Low Demand Mode ..................................................................................6
2.1.2 High Demand Mode .................................................................................6
2.1.3 Safe Failure Fraction.................................................................................6
2.2 Assumptions .................................................................................................7
2.3 Safety Function and Safe State .....................................................................8
2.4 Characteristic Safety Values .........................................................................9
3 Safety Recommendation.................................................. 10
3.1 Interfaces ....................................................................................................10
3.2 Configuration ..............................................................................................10
3.3 Useful Life Time ..........................................................................................10
3.4 Installation and Commissioning ..................................................................11
4 Proof Test .......................................................................... 12
4.1 Proof Test Procedure ..................................................................................12
5 Abbreviations.................................................................... 14

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Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Introduction
1Introduction
1.1 General Information
This manual contains information for application of the device in functional safety
related loops.
The corresponding data sheets, the operating instructions, the system
description, the Declaration of Conformity, the EC-Type-Examination Certificate,
the Functional Safety Assessment and applicable Certificates (see data sheet)
are integral parts of this document.
The documents mentioned are available from www.pepperl-fuchs.com or by
contacting your local Pepperl+Fuchs representative.
Mounting, installation, commissioning, operation, maintenance and disassembly
of any devices may only be carried out by trained, qualified personnel. The
instruction manual must be read and understood.
When it is not possible to correct faults, the devices must be taken out of service
and action taken to protect against accidental use. Devices should only be
repaired directly by the manufacturer. De-activating or bypassing safety functions
or failure to follow the advice given in this manual (causing disturbances or
impairment of safety functions) may cause damage to property, environment or
persons for which Pepperl+Fuchs GmbH will not be liable.
The devices are developed, manufactured and tested according to the relevant
safety standards. They must only be used for the applications described in the
instructions and with specified environmental conditions, and only in connection
with approved external devices.
1.2 Intended Use
The devices are available as safe area version (KCD2-STC-1.HC(.SP)) where
they can be used as a signal conditioner providing isolation for non-intrinsically
safe applications. Also the devices are available as hazardous area version
(KCD2-STC-Ex1.HC(.SP), HiC2025HC) allowing use as isolated barriers for
intrinsic safety applications.
The device supplies 2-wire transmitters in the field, and can also be used with
current sources.
It transfers the analog input signal to the safe area as an isolated current value.
Bi-directional communication is supported for SMART transmitters that use
current modulation to transmit data and voltage modulation to receive data.
The output is selected as a current source, current sink, or voltage source via
DIP switches.
In the KCD2-STC-(Ex)1.HC(.SP) test sockets for the connection of
HART communicators are integrated into the terminals of the device.

Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Introduction
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The KC devices are available with screw terminals or spring terminals. The type
code of the versions of the KC-devices with spring terminals has the
extension ".SP".
The KCD2-STC-(Ex)1.HC(.SP) is a single device for DIN rail mounting while the
HiC2025HC is a plug-in device to be inserted into a specific Termination Board.
1.3 Manufacturer Information
Pepperl+Fuchs GmbH
Lilienthalstrasse 200, 68307 Mannheim, Germany
Up to SIL2
1.4 Relevant Standards and Directives
Device specific standards and directives
Functional safety IEC 61508 part 2, edition 2000:
Standard of functional safety of electrical/electronic/programmable electronic
safety-related systems (product manufacturer)
Electromagnetic compatibility:
- EN 61326-1:2006
- NE 21:2006
System specific standards and directives
Functional safety IEC 61511 part 1, edition 2003:
Standard of functional safety: safety instrumented systems for the process
industry sector (user)
KCD2-STC-1.HC(.SP)
KCD2-STC-Ex1.HC(.SP)
HiC2025HC

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Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Planning
2 Planning
2.1 System Structure
2.1.1 Low Demand Mode
If there are two 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 Failure on Demand) and
Tproof (proof test interval that has a direct impact on the PFDavg)
the SFF value (Safe Failure Fraction)
the HFT architecture (Hardware Fault Tolerance architecture)
2.1.2 High Demand Mode
If there is only one loop, which combines the standard operation and safety
related operation, then usually the demand rate for this loop is assumed to be
higher than once per year.
The relevant safety parameters to be verified are:
PFH (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 architecture)
2.1.3 Safe Failure Fraction
The safe failure fraction describes the ratio of all safe failures and dangerous
detected failures to the total failure rate.
SFF = (λs+ λdd) / (λs+ λdd + λdu)
A safe failure fraction as defined in 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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2.2 Assumptions
The following assumptions have been made during the FMEDA analysis:
The device shall claim less than 10 % of the total failure budget for a
SIL2 safety loop.
For a SIL2 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 SIL2 application operating in High Demand Mode of operation 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.
Failure rate based on the Siemens SN29500 data base.
Failure rates are constant, wear out mechanisms are not included.
External power supply failure rates are not included.
The safety-related device is considered to be of type Acomponents with a
Hardware Fault Tolerance of 0.
Since the circuit has a Hardware Fault Tolerance of 0and it is a type A
component, the SFF must be > 60 % according to table 2 of IEC 61508-2 for
SIL2 (sub)system.
The stress levels are average for an industrial environment and can be
compared to the Ground Fixed Classification of MIL-HNBK-217F.
Alternatively, the assumed environment is similar to:
• IEC 60654-1 Class C (sheltered location) with temperature limits within
the manufacturer's rating and an average temperature over a long period
of time of 40 ºC. Humidity levels are assumed within manufacturer's
rating. For a higher average temperature of 60 ºC, the failure rates should
be multiplied with an experience based factor of 2.5. A similar multiplier
should be used if frequent temperature fluctuation must be assumed.
During normal operation any change of the operating function (DIP switch
modification) must be prevented.
It was assumed that the appearance of a safe error (e. g. output in safe state)
would be repaired within 8 hours (e. g. remove sensor burnout).
During the absence of the device for repairing, measures have to be taken to
ensure the safety function (for example: substitution by an equivalent device).
The HART protocol is only used for setup, calibration, and diagnostic
purposes, not during normal operation.
The application program in the logic solver must be configured to detect
underrange and overrange failures.

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Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Planning
2.3 Safety Function and Safe State
Safety Function
The safety function of the device is fulfilled, as long as the output repeats the input
current (4 mA ... 20 mA) with a tolerance of 2 %.
Therefore the DIP switch settings used in safety relevant applications are:
DIP Switch Settings KCD2-STC-(Ex)1.HC(.SP)
DIP Switch Settings HiC2025HC
Safe State
The safe state is defined as the output reaching values < 3.6 mA/0.9 V
or > 20.5 mA/5.125 V.
Reaction Time
The reaction time for all safety functions is < 20 ms.
Function S1 S2 S3 S4
Current source 4 mA ... 20 mA II II III
Voltage source 1 V... 5 V II II I I
Current sink 4 mA ... 20 mA II III II
Ta b l e 2 . 1
Function S1 S2 S3 S4
Current source 4 mA ... 20 mA OFF OFF ON OFF
Voltage source 1 V... 5 V OFF OFF ON ON
Current sink 4 mA ... 20 mA OFF ON OFF OFF
Ta b l e 2 . 2

Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Planning
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2.4 Characteristic Safety Values
The characteristic safety values like PFD, SFF, HFT and Tproof are taken from the
SIL report/FMEDA report. Please note, PFD and Tproof are related to each other.
The function of the devices has to be checked within the proof test interval
(Tproof).
Parameters acc. to IEC 61508 Values
Assessment type and documentation FMEDA report
Device type A
Mode of operation Low Demand Mode or High Demand Mode
HFT 0
SIL 2
Safety function Signal transfer
λs126.3 FIT
λdd 0 FIT
λdu 50.3 FIT
λno effect 228.3 FIT
λtotal (safety function) 405 FIT
λnot part 32.2 FIT
SFF 87.58 %
MTBF 1261 years
PFH 5.03 x 10-8 1/h
PFDavg for Tproof = 1 year 2.20 x 10-4
PFDavg for Tproof = 2 years 4.41 x 10-4
PFDavg for Tproof = 5 years 1.10 x 10-3
Reaction time 2< 20 ms
1acc. to SN29500. This value includes failures which are not part of the safety function.
2Time between fault detection and fault reaction.
Ta b l e 2 . 3

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Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Safety Recommendation
3 Safety Recommendation
3.1 Interfaces
The device has the following interfaces. For corresponding terminals see data
sheet.
Safety relevant interfaces: input I, output I
Non-safety relevant interfaces: none
The HART communication is not relevant for functional safety.
3.2 Configuration
The device must be configured through the user accessible DIP switches for the
required output function before the start-up. During the functionality any change of
the operating function (DIP switch modification) can invalidate the safety function
behavior and must be avoided.
The KCD2 devices provide a suitable cover to protect against accidental changes
while on the HiC devices the access to the DIP switch is permitted only through a
small window on the side and by a small screw driver.
3.3 Useful Life Time
Although a constant failure rate is assumed by the probabilistic estimation this
only applies provided that the useful life time of components is not exceeded.
Beyond this useful life time, the result of the probabilistic calculation is
meaningless as the probability of failure significantly increases with time. The
useful life time 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 working 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 life time of each component.
It is assumed that early failures are detected to a huge percentage during the
installation period and therefore the assumption of a constant failure rate during
the useful life time is valid.
However, according to IEC 61508-2, a useful life time, based on experience,
should be assumed. Experience has shown that the useful life time often lies
within a range period of about 8 ... 12 years.

Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Safety Recommendation
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Our experience has shown that the useful life time of a Pepperl+Fuchs product
can be higher
if there are no components with reduced life time in the safety path (like
electrolytic capacitors, relays, flash memory, opto coupler) which can produce
dangerous undetected failures and
if the ambient temperature is significantly below 60 °C.
Please note that the useful life time refers to the (constant) failure rate of the
device. The effective life time can be higher.
3.4 Installation and Commissioning
Installation has to consider all aspects regarding the SIL level of the loop. During
installation or replacement of the device the loop has to shut down. Devices have
to be replaced by the same type of devices.

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Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Proof Test
4 Proof Test
4.1 Proof Test Procedure
According to IEC 61508-2 a recurring proof test shall be undertaken to reveal
potentially dangerous failures that are otherwise not detected by diagnostic tests.
The functionality of the subsystem must be verified at periodic intervals
depending on the applied PFDavg in accordance with the data provided in this
manual. See chapter 2.4.
It is under the responsibility of the operator to define the type of proof test and the
interval time period.
With the following instructions a proof test can be performed which will reveal
almost all of the possible dangerous faults (diagnostic coverage > 90 %).
The ancillary equipment required:
• Digital multimeter with an accuracy better than 0.1 %
For the proof test of the intrinsic safety side of the devices, a special
digital multimeter for intrinsic safety circuits must be used. Intrinsic safety
circuits that were operated with circuits of other types of protection may
not be used as intrinsically safe circuits afterwards.
• Power supply set at nominal voltage of 24 V DC
• Process calibrator with mA current source/sink feature (accuracy better
than 20 µA)
The entire measuring loop must be put out of service and the process held in
safe condition by means of other measures.
Prepare a test set-up for testing the KCD2-STC-(Ex)1.HC(.SP) device
( see Figure 4.1 on page 13) or for testing the HiC2025HC device
( see Figure 4.2 on page 13). Choose the proper input terminals (passive
input or active input) in accordance with the specific application and follow the
steps indicated in the table below.
Restore the safety loop. Any by-pass of the safety function must be removed.
Step No. Set input value (mA) Measurement point
Output value (mA) Across 2-wire Tx (V) Across 4-wire Tx (V)
120.00 20.00 ±0.4 15.1 ±0.4 2.2 ±1.1
212.00 12.00 ±0.4 16.1 ±0.4 2.2 ±1.1
34.00 4.00 ±0.4 17.1 ±0.4 2.2 ±1.1
4* 23.00 23.00 ±0.4 14.5 ±0.5 2.2 ±1.1
5* 0< 0.2 19.0 ±1.0 n.a.
612.00
* The output value shall detect a Fail High, Fail Low condition.
Table 4.1 Steps to be performed for the proof test

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Proof Test
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Figure 4.1 Proof test set-up KCD2-STC-(Ex)1.HC(.SP)
Usage in Zone 0, 1, 2/Div. 1, 2 only for KCD2-STC-Ex1.HC(.SP)
Figure 4.2 Proof test set-up for HiC2025HC
KCD2-STC-Ex1.HC
6+
5-
3+
4-
1+
2-
Zone 0, 1, 2
Div. 1, 2
Zone 2
Div. 2
Multimeter
(V)
Multimeter
(V)
4 mA ... 20 mA
4 mA ... 20 mA
I
supply
Passive
input
Input sensor
(4-wire Tx
externally
powered)
Active
input
Input sensor
(2-wire Tx
loop powered)
9+
10-
24 V DC
Power
supply
Logic
solver
analog
input
Current output or
Voltage output or
Current sink
Supply
HiC2025HC
11+
14-
5-
1+
4-
1b
SL2
5a
5b
SL1
8a
7a
Termination Board
Zone 0, 1, 2
Div. 1, 2
Zone 2
Div. 2
Multimeter
(V)
Multimeter
(V)
4 mA ... 20 mA
4 mA ... 20 mA
I
supply
Passive
input
Input sensor
(4-wire Tx
externally
powered)
Active
input
Input sensor
(2-wire Tx
loop powered)
Supply +
Supply -
24 V DC
Power
supply
Logic
solver
analog
input
Current output or
Voltage output or
Current sink
Supply
Bus
Tip
Normally the easiest way to test H-System modules is by using a stand-alone
HiCTB08-UNI-SC-SC Termination Board. The tester then has no need to
disconnect wires in the existing application, so subsequent miswiring of the
module is prevented.

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Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Abbreviations
5 Abbreviations
DCS Distributed Control System
ESD Emergency Shutdown
FIT Failure In Time
FMEDA Failure Mode, Effects and Diagnostics Analysis
λsProbability of safe failure
λdd Probability of dangerous detected failure
λdu Probability of dangerous undetected failure
λno effect Probability of failures of components in the safety path that have
no effect on the safety function
λnot part Probability of failure of components that are not in the safety path
λtotal (safety function) Safety function
HFT Hardware Fault Tolerance
MTBF Mean Time Between Failures
MTTR Mean Time To Repair
PFDavg Average Probability of Failure on Demand
PFH Probability of dangerous Failure per Hour
PTC Proof Test Coverage
SFF Safe Failure Fraction
SIF Safety Instrumented Function
SIL Safety Integrity Level
SIS Safety Instrumented System
Tproof Proof Test Interval

Safety Manual SIL KCD2-STC-(Ex)1.HC(.SP), HiC2025HC
Notes
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Subject to modifications
Copyright PEPPERL+FUCHS • Printed in Germany
www.pepperl-fuchs.com
PROCESS AUTOMATION –
PROTECTING YOUR PROCESS
Worldwide Headquarters
Pepperl+Fuchs GmbH
68307 Mannheim · Germany
Tel. [phone]
E-mail: [email protected]
For the Pepperl+Fuchs representative
closest to you check www.pepperl-fuchs.com/contact
TDOCT-2750_ENG
07/2012