Hazardous Area Signal Conditioning Solution – Pepperl+Fuchs KCD2-STC-1 | KCD2 Series
In process plants, refineries, and chemical facilities where explosive atmospheres are a daily reality, engineers cannot afford to compromise on signal integrity or personnel safety. The Pepperl+Fuchs KCD2-STC-1 isolated barrier power supply module is the industry-standard solution for powering and conditioning 2-wire transmitters in Zone 1 / Zone 2 hazardous locations — delivering clean, isolated 24 V DC loop power with galvanic separation between the safe area and the field.
Where This Product Is Used
The KCD2-STC-1 is specified by process engineers and instrumentation designers across a wide range of safety-critical industries and applications:
- Oil & Gas Upstream / Midstream: Wellhead pressure and temperature transmitter loops in Zone 1 classified areas; pipeline SCADA RTU panels requiring intrinsically safe field wiring.
- Petrochemical & Refinery: Reactor vessel level and flow measurement loops; DCS marshalling cabinets interfacing with Ex ia field instruments.
- Chemical Processing: Batch reactor monitoring; solvent storage tank level gauging where IEC 60079-11 compliance is mandatory.
- Pharmaceutical Manufacturing: Clean-room and solvent-handling areas requiring ATEX / IECEx certified signal conditioning for FDA-regulated process loops.
- Water & Wastewater Treatment: Pump station wet-well level transmitter loops; chlorine dosing area instrumentation panels.
- Power Generation: Turbine lube-oil system instrumentation; hydrogen-cooled generator monitoring loops.
- Marine & Offshore: Hazardous zone instrument panels on FPSOs and offshore platforms requiring DNV-GL or ABS certified barriers.
Technical Specifications
| Part Number | KCD2-STC-1 |
| Manufacturer | Pepperl+Fuchs GmbH |
| Series | KCD2 — K-System Isolated Barriers |
| Function | Isolated Barrier / 2-Wire Transmitter Power Supply |
| Supply Voltage | 20–35 V DC (from KF-PS power rail or external) |
| Output (Field Side) | Isolated 24 V DC loop supply for 2-wire (4–20 mA) transmitters |
| Signal Range | 4–20 mA (NAMUR / standard transmitter compatible) |
| Galvanic Isolation | Input / Output / Power — 3-way isolation, 500 V AC test voltage |
| Hazardous Area Classification | Ex ia IIC / IIB — Zone 0, 1, 2 (ATEX / IECEx) |
| Safe Area Output | 4–20 mA signal to DCS / PLC / recorder |
| Mounting | DIN rail (35 mm), K-System backplane compatible |
| Housing Width | 20 mm (single-width K-System module) |
| Operating Temperature | -20 °C to +60 °C |
| Protection Class | IP20 |
| Weight | Approx. 100 g |
| Certifications | ATEX, IECEx, cULus, FM |
Why Engineers Specify This Model
- True 3-Way Galvanic Isolation: Eliminates ground loops and common-mode interference — critical in large process plants with multiple earthing points across long cable runs.
- Universal DIN Rail Mounting: Slots directly into the Pepperl+Fuchs K-System backplane for shared power bus and collective error signalling — reducing panel wiring time by up to 60%.
- Plug-In Terminal Design: Front-accessible screw terminals allow module replacement without disconnecting field wiring — minimising plant downtime during maintenance windows.
- Broad Hazardous Area Coverage: Certified for Zone 0 field devices (Ex ia IIC), providing the highest level of intrinsic safety for the most demanding gas group environments including hydrogen (Group IIC).
- Compact 20 mm Footprint: High channel density in marshalling cabinets — a full 32-channel loop panel can be built in under 700 mm of DIN rail.
- LED Status Indication: Green power LED and red fault LED provide instant visual diagnostics without test equipment.
- Long-Term Availability: Active product in the Pepperl+Fuchs K-System portfolio — spare parts and replacements available for 10+ year plant lifecycles.
Complete System Bill of Materials
The KCD2-STC-1 is designed to operate within the Pepperl+Fuchs K-System ecosystem. A complete loop typically requires:
- KCD2-STC-1 — Isolated barrier / transmitter power supply (this module)
- KF-PS2.230 / KF-PS2.24 — K-System power supply unit (230 V AC or 24 V DC input)
- KF-RS — DIN rail segment / backplane bus connector
- KF-CON5 / KF-CON8 — Collective error signal module (optional, for panel-level fault annunciation)
- KF-CP — Coding plug set (for module identification and replacement verification)
- Field Instrument: Any ATEX / IECEx certified 2-wire 4–20 mA transmitter (pressure, temperature, level, flow)
- DCS / PLC Input Card: Standard 4–20 mA analogue input module (no special Ex-rated card required on safe side)
Contact Konmask for complete panel BOM quotations and cross-reference assistance.
Compliance & Industry Standards
- ATEX Directive 2014/34/EU — II (1) G Ex ia IIC / IIB Ga/Gb
- IECEx Scheme — IECEx PTB (refer to current certificate)
- IEC 60079-11 — Intrinsic Safety ia — Equipment for explosive gas atmospheres
- IEC 61010-1 — Safety requirements for electrical equipment for measurement and control
- EN 50020 — Electrical apparatus for potentially explosive atmospheres
- cULus / FM Approved — North American hazardous location compliance (Class I, Division 1 & 2)
- RoHS Compliant — Restriction of Hazardous Substances Directive
Quality Assurance & Sourcing
Konmask sources the KCD2-STC-1 exclusively through authorised distribution channels and verified surplus inventory from decommissioned plant projects. Every unit undergoes our pre-shipment inspection protocol:
- Visual inspection — housing integrity, terminal condition, label legibility
- Certification label verification — ATEX / IECEx marking cross-checked against published certificate database
- Functional continuity check — loop power output verified at 24 V DC under 4–20 mA load
- Packaging — anti-static bag, foam-lined carton, humidity indicator card
- Documentation — original datasheet, certificate copy, and Konmask inspection report included
How to Source This Part
- Single Units: Add to cart and checkout — ships within 1–3 business days from our Hong Kong / Xiamen warehouse.
- Project Quantities (10+ units): Contact [email protected] for volume pricing and lead time confirmation.
- Emergency / Shutdown Supply: Mark your enquiry URGENT — we prioritise same-day quotation for plant shutdown situations.
- Cross-Reference / Replacement: If you are replacing a different barrier model, send us your existing part number and we will confirm compatibility.
- Global Shipping: DHL Express, FedEx International Priority, and sea freight consolidation available. Export documentation (CO, packing list, commercial invoice) provided for all international orders.
Application-Specific FAQ
Q: Can the KCD2-STC-1 power a HART-enabled transmitter?
A: Yes. The module is transparent to HART FSK signals (1200 / 2200 Hz) superimposed on the 4–20 mA loop. A HART modem can be connected in parallel on the safe-area side without modification.
Q: What is the maximum field cable length / capacitance?
A: The intrinsic safety parameters (Uo, Io, Po, Co, Lo) are defined in the ATEX certificate. For IIC gas groups, maximum field cable capacitance is typically 83 nF and inductance 3.3 mH — sufficient for most plant cable runs up to several hundred metres. Always verify against your specific cable parameters.
Q: Can I use this module in a Zone 0 location?
A: The KCD2-STC-1 is a safe-area mounted device. The field instrument it powers can be installed in Zone 0 (Ex ia IIC Ga), provided the instrument itself carries the appropriate Zone 0 certification.
Q: Is the KCD2-STC-1 compatible with the older KCD2-STC (without the -1 suffix)?
A: The -1 suffix denotes the single-channel version. Mechanically and electrically compatible with the same K-System backplane. Verify your existing certificate and entity parameters before substitution in a certified installation.
Q: Do you supply the full K-System panel assembly?
A: Yes. Konmask can supply complete marshalling panel assemblies including power supply, barriers, DIN rail, and enclosure. Contact us with your I/O list for a turnkey quotation.
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