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ISO

9001

Functional Safety

Temperature Converter

KCD2-UT2-(Ex)1, HiC2081

PROCESS AUTOMATION

MANUAL

Summary of Contents for HiC2081

Page 1: ...ISO9001 2 Functional Safety Temperature Converter KCD2 UT2 Ex 1 HiC2081 PROCESS AUTOMATION MANUAL ...

Page 2: ...very 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 ...

Page 3: ...tandards 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 ...

Page 4: ...shooting 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 informatio...

Page 5: ...ad 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 ...

Page 6: ...s 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...

Page 7: ...e 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 P...

Page 8: ...ds 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 ...

Page 9: ...y 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 fai...

Page 10: ...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 failur...

Page 11: ...y function of the device is fulfilled as long as the output repeats the linearized input signal with a tolerance of 2 Safe State The safe state is present when the output signal is 4 mA or 20 mA Reaction Time for temperature input 1 5 s for potentiometer input 3 s Note See corresponding datasheets for further information ...

Page 12: ...the following rules apply Annunciation failures have no direct influence on the safety function and are therefore counted as No effect failures 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 20 1 FIT dd 293 FIT du 69 FIT no part 27 6 FIT total safety function 2 382 FIT SFF 2 81 8 PTC 90 MTBF 3 3 acc t...

Page 13: ...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 experi...

Page 14: ...e K ADP USB adapter to the device 3 Configure the device for the required safety function via the PACTware operating software see chapter 4 1 1 4 Protect the device configuration by a password against changing 5 Leave the parameterization mode to prevent unintentional adjustments 6 Disconnect the personal computer from the device 7 Close the cover 8 Check the device configuration to ensure the exp...

Page 15: ... the proof test The proof test reveals almost all possible dangerous faults diagnostic coverage 90 Check the settings after the configuration by suitable tests 5 2 Proof Test Procedure for KCD2 UT2 Ex 1 Perform the proof test with the same configuration that you use in the application Substitute the sensor with a sensor simulator or a calibrator Check the safety function at the input which must be...

Page 16: ...lication 11 7 mA to 12 3 mA for the 20 mA application 19 7 mA to 20 3 mA 7 Remove the TC simulator Check if a lead breakage is detected The red LED is flashing The output behavior in the event of a fault depends on the device configuration 8 Remove the fixed resistor Check if a lead breakage of the cold junction compensation is detected The red LED is flashing The output behavior in the event of a...

Page 17: ...ED is flashing The output behavior in the event of a fault depends on the device configuration 10 Set the device back to the original settings after the test Proof Test for external Cold Junction Compensation You can also use this proof test if you are using an external cold junction compensation In this case set the preset compensation reference temperature on the TC simulator see step 3 ...

Page 18: ...o 20 3 mA 5 Apply a short circuit between terminal 3 and 4 Do not remove the RTD simulator Check if a short circuit of the cold junction compensation is detected The red LED is flashing The output behavior in the event of a fault depends on the device configuration 6 Remove the RTD simulator Check if a lead breakage is detected The red LED is flashing The output behavior in the event of a fault de...

Page 19: ... 3 mA for the 20 mA application 19 7 mA to 20 3 mA 5 Remove the voltage source Check if a lead breakage is detected The red LED is flashing The output behavior in the event of a fault depends on the device configuration 6 Set the device back to the original settings after the test Zone 0 1 2 Div 1 2 Zone 2 Div 2 Fault KCD2 UT2 Ex1 4 3 2 1 5 6 7 8 Multimeter mA mV Supply Supply 24 V DC Power supply...

Page 20: ... current The proof test is passed if the following values are measured at the output 1 for 0 of the potentiometer value 3 7 mA to 4 3 mA for 50 of the potentiometer value 11 7 mA to 12 3 mA for 100 of the potentiometer value 19 7 mA to 20 3 mA 4 Remove the series resistors 5 Set the device back to the original settings after the test Zone 0 1 2 Div 1 2 Zone 2 Div 2 Fault KCD2 UT2 Ex1 4 3 2 1 5 6 7...

Page 21: ...pecified for the output as a current source are also valid for the output as current sink In addition to the test setup described above a voltage source must be connected to the output to simulate the original application Proof Test Coverage PTC The proof test coverage of the device is assumed to be 90 With du 69 FIT of the device the proof test can therefore only detect 62 FIT ...

Page 22: ...r 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 TC simulator RTD simulator voltage source or resistor Termination board Tip The easiest way to test HiC dev...

Page 23: ... 20 mA application 19 7 mA to 20 3 mA 7 Remove the TC simulator Check if a lead breakage is detected The red LED is flashing The output behavior in the event of a fault depends on the device configuration 8 Remove the fixed resistor Check if a lead breakage of the cold junction compensation is detected The red LED is flashing The output behavior in the event of a fault depends on the device config...

Page 24: ...ED is flashing The output behavior in the event of a fault depends on the device configuration 10 Set the device back to the original settings after the test Proof Test for external Cold Junction Compensation You can also use this proof test if you are using an external cold junction compensation In this case set the preset compensation reference temperature on the TC simulator see step 3 ...

Page 25: ...etween terminal 1 and 4 Do not remove the RTD simulator Check if a short circuit of the cold junction compensation is detected The red LED is flashing The output behavior in the event of a fault depends on the device configuration 6 Remove the RTD simulator Check if a lead breakage is detected The red LED is flashing The output behavior in the event of a fault depends on the device configuration 7...

Page 26: ...7 mA to 20 3 mA 5 Remove the voltage source Check if a lead breakage is detected The red LED is flashing The output behavior in the event of a fault depends on the device configuration 6 Set the device back to the original settings after the test 11 14 1 2 5 4 HiC2081 Termination Board Zone 0 1 2 Fault SL2 5a 1a 1b 5b SL1 8a 7a Multimeter mA mV Supply Supply 24 V DC Power supply I supply Supply Bu...

Page 27: ...f the following values are measured at the output 1 for 0 of the potentiometer value 3 7 mA to 4 3 mA for 50 of the potentiometer value 11 7 mA to 12 3 mA for 100 of the potentiometer value 19 7 mA to 20 3 mA 4 Remove the series resistors 5 Set the device back to the original settings after the test 11 14 1 2 5 4 HiC2081 Termination Board Zone 0 1 2 Fault SL2 5a 1a 1b 5b SL1 8a 7a 50 0 100 Multime...

Page 28: ...pecified for the output as a current source are also valid for the output as current sink In addition to the test setup described above a voltage source must be connected to the output to simulate the original application Proof Test Coverage PTC The proof test coverage of the device is assumed to be 90 With du 69 FIT of the device the proof test can therefore only detect 62 FIT ...

Page 29: ...replaced If the safety loop does not work without the device shut down the application Do not restart the application without taking proper precautions Secure the application against accidental restart 3 Do not repair a defective device A defective device must only be repaired by the manufacturer 4 Replace a defective device only by a device of the same type Danger Danger to life from missing safe...

Page 30: ...t Probability of failure of components that are not in the safety loop total safety function Probability of failure of components that are in the safety loop HFT Hardware Fault Tolerance MTBF Mean Time Between Failures MTTR Mean Time To Restoration PCS Process Control System PFDavg Average Probability of dangerous Failure on Demand PFH Average frequency of dangerous failure PLC Programmable Logic ...

Page 31: ...Functional Safety KCD2 UT2 Ex 1 HiC2081 Notes 2018 02 31 ...

Page 32: ...erl fuchs com Worldwide Headquarters Pepperl Fuchs GmbH 68307 Mannheim Germany Tel 49 621 776 0 E mail info de pepperl fuchs com For the Pepperl Fuchs representative closest to you check www pepperl fuchs com contact PROCESS AUTOMATION PROTECTING YOUR PROCESS DOCT 5949A 02 2018 ...

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