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Engineer’s Guide
Preface..................................................................9 Section 5
Section 1 Intrinsically Safe Systems. ........................................ 30
Hazardous Location Apparatus...................................................... 30
Introduction to Intrinsic Safety...........................9
Non Hazardous Location Apparatus.............................................. 31
Ignition Triangle................................................................................ 9
Connecting Cables......................................................................... 31
Explosive Mixture Characteristics.................................................. 10
Analysis of Intrinsically Safe Systems............................................ 32
Ignition Temperature....................................................................... 10
Combination Barriers..................................................................... 33
Flash-point Temperature................................................................ 10
The Use of Multiconductor Cables................................................ 35
Evaluation of the Risk of Explosion................................................ 10
Historical Growth of Electrical Safety Standards........................... 11 Section 6
Section 2 Installation of Intrinsically Safe .
Hazardous (Classified) Locations and and Associated Apparatus. ....................................... 35
Protection Ratings for Enclosures.................................................. 36
Apparatus. ........................................................................ 12
Cable Capacitance and Inductance............................................... 36
The Classification of Hazardous Locations for Divisions............... 12
Grounding of Intrinsically Safe Plants............................................ 37
The Classification of Apparatus for Divisions................................. 13
Grounding of Passive Barriers....................................................... 37
Surface Temperature Classification for Divisions........................... 14
Grounding of Shielded Cables....................................................... 38
The Classification of Hazardous Locations for Zones.................... 14
The Classification of Apparatus for Zones..................................... 15 Section 7
Surface Temperature Classification for Zones............................... 15 Maintenance of Safe Plants..................................... 39
ATEX Summary............................................................................... 15 Initial Inspection............................................................................. 39
Differences Between Division and Zone Practices........................ 15 Programmed Maintenance............................................................. 41
Apparatus Failure and Repairs....................................................... 42
Section 3
Methods of Protection. ............................................... 16 Section 8
Explosion-proof Enclosure............................................................. 17 Application Theory.............................................43
Purging or Pressurization Method.................................................. 18 Passive Zener Barriers................................................................... 43
Encapsulation................................................................................. 19 Loop-powered Isolated Barriers.................................................... 43
Oil-immersion Protection Method.................................................. 19 Powered Isolated Barriers.............................................................. 44
Powder-filling Protection Method................................................... 19 Barrier Choice Criteria.................................................................... 44
Sealing, Limited-breathing and Dust-proofing Application Examples..................................................................... 46
Protection Methods........................................................................ 20
Increased Safety Protection Method.............................................. 20
Section 9
Intrinsic Safety Protection Method................................................. 20
Practical Solutions.............................................49
Switches and NAMUR Sensors..................................................... 49
Non Incendive or Simplified Protection Method............................ 21
Transmitters.................................................................................... 51
Mixed Protection Methods............................................................. 21
SMART Transmitters...................................................................... 53
Summary of Protection Methods................................................... 21
I/P Converters................................................................................ 54
Comparisons Between the Most Widely Used
Protection Methods........................................................................ 22 SMART I/P Converters................................................................... 55
Thermocouples.............................................................................. 56
Section 4 RTDs............................................................................................... 57
The Philosophy of Intrinsic Safety......................... 23
Strain Gauges................................................................................. 59
The Intrinsically Safe Circuit........................................................... 23
Vibration Monitoring....................................................................... 59
Resistive Circuits........................................................................... 23
Potentiometers............................................................................... 60
Inductive Circuits............................................................................ 24
LED Clusters, Solenoids and ALarms............................................ 61
Capacitive Circuits......................................................................... 25
Pulse Input/Serial Communication................................................. 63
Classification of Intrinsically Safe Electrical Apparatus................. 26
Logic Controls/Limit Alarms........................................................... 64
Electrical Apparatus Categories..................................................... 26
Power Supplies.............................................................................. 65
Intrinsic Safety in the North American System............................... 27
Design and Construction Aspects of
Intrinsically Safe Apparatus............................................................ 27
Intrinsic Safety Barriers.................................................................. 28
Section 10
Intrinsic Safety: Future Trends..........................68
Evolving Technology....................................................................... 68
Strategies in Communication Protocol.......................................... 68
International Standards.................................................................. 68
Section 11
Safety Integrity Level (SIL) Overview................69
Functional Safety for Signal Generation,
Signal Transmission and Signal Evaluation.................................... 69
What Does This Mean for You as the Customer
and Equipment User?.................................................................... 69
What Must You Comply With?....................................................... 69
The First Step - Analysis ............................................................... 69
Reduction of Risk .......................................................................... 70
Organizational Measures . ............................................................. 70
Important Recommended Values in Practical Application............. 70
Notes on Equipment Selection ..................................................... 70
A SIL Evaluation by Pepperl+Fuchs–All the Facts
About Functional Safety at a Glance.............................................. 71
Where Can You Find the Necessary SIL Value?............................. 72
What Are the Advantages of Using the Pepperl+Fuchs
Standard Devices?......................................................................... 72
The Optional Safety Classifications SIL1 to SIL4:
What Should Be Noted?................................................................ 72
Devices for Applications in the Safety Grading SIL1..................... 72
Devices for Applications in the Safety Grading SIL2..................... 73
Devices for Applications in the Safety Grading SIL3..................... 73
Devices for Applications in the Safety Grading SIL4..................... 73
Which Devices Can Be Used for Functional Safety?..................... 73
Special Item - Isolating Switch Amplifier
with Dynamic Evaluation................................................................ 73
Section 12
Additional Information.......................................75
Bibliography................................................................................... 75
Reference Standards...................................................................... 75
Internet Resources......................................................................... 76
North American Enclosure
Protection Ratings.......................................................................... 77
Enclosure Protection Degrees
(European Rating System).............................................................. 79
Minimum Ignition Curves............................................................... 80
US Recognized Testing Laboratories............................................. 85
Recognized Certifying Authorities.................................................. 87
Glossary......................................................................................... 89
0.01
In addition to the nominal rating of materials under consideration,
0 10 0 0 0 0 0 0 0 90 100
parameters related to the process involved are especially
VOLUME.CONCENTRATION.(%)
important in the evaluation. As an example, the risk of explosion
LEL UEL
may be caused by the evaporation of a liquid or by the presence
of liquid sprayed under high pressure.
Figure 1.3
It is also important to know what atmospheric conditions are
Ignition energy in relation to hydrogen and present normally and abnormally. The range of concentration
propane air/gas concentration between the explosion limits generally increases as the pressure
and temperature of the mixture increases. The relationship
For a concentration lower than the one corresponding to the MIE, between explosion limits and flash point for ethyl alcohol is
the quantity of energy required to ignite the mixture increases until illustrated in Figure 1.4.
a concentration value is reached below which the mixture cannot
be ignited due to the low quantity of fuel. This value is called the
lower explosive limit (LEL). In the same way, when increasing
the concentration the energy requirement increases, and a
concentration value is identified above which ignition cannot
occur due to the low quantity of an oxidizer. This value is called
the upper explosive limit (UEL).
100
Explosible
Partial pressure P
rve
mixture
cu
80 standards. Up until that time, rules and regulations were created
re
10 (combustion
su
by individuals (designers, engineers, government agencies, etc.)
es
B explosive with flame
pr
8 60
or
p propagation trying to be safe. However, with the increase in demand for more
Va
6
40
= explosion ) and more complex electronic equipment for use in hazardous
4 Lower explosion limit locations, a movement began toward the standardization of safety
2
20 Non-combustible requirements.
C too poor mixture (neither
0 0 combustible nor Many organizations, including NFPA, NEC, ISA, UL, FM, CSA,
0 10 20 30 40 50 ºC explosive) NEMA, IEC, BASEEFA, PTB, and CENELEC, perform different
Flash point functions in ensuring the safety of industrial plants and refineries
Lower explosion limit Upper explosion limit (refer to Appendix C, Glossary, for definitions of acronyms).
Figure 1.4 When reference books about standards and safety requirements
become too confusing, just remember that the operative word
Graph representing the vapor pressure of ethyl alcohol
here is safety.
The following illustrates a fuel tank with fixed lid and breather, The Classification of Apparatus for Divisions
which is typical of a North American Class I hazardous location.
Intrinsically Safe Apparatus
Class.I,.Division.
According to Article 504 of the United States’ National Electrical
(From 5-ft to 10-ft radius)
Class.I,.Division.1 Code, apparatus can be classified as intrinsically safe when all the
(5-ft radius around vent) circuits are intrinsically safe; i.e., containing circuits in which any
spark or thermal effect is incapable of causing ignition of a mixture
of flammable or combustible material in air under prescribed test
Vent conditions.
Outdoors
Gasoline
10 ft storage 10 ft
Pressure, temperature and flow transmitters, solenoid valves, I/P
tank converters and other instrumentation are typical of intrinsically
without safe apparatus.
floating Circular dike
around tank
roof Associated Apparatus
Associated apparatus can be defined as apparatus in which the
“circuits are not necessarily intrinsically safe themselves, but that
Class.I,.Division. affect the energy in the intrinsically safe circuits and are relied on
to maintain intrinsic safety.” Associated apparatus is classified
Figure 2.1 as either:
Schematic of the classification of a Class I hazardous
1. Electrical apparatus having an alternative type protection
location fuel tank with fixed lid and breather
for use in the appropriate hazardous location; or
2. Electrical apparatus not protected and therefore must not
Class II (Combustible Dusts or Powders) be used within a hazardous location.
Class II hazardous locations are subdivided into the following Intrinsic safety barriers are typical of associated apparatus.
three groups, depending on the type of combustible dusts or These barriers must be placed in non hazardous locations (unless
powders present: protected by other suitable methods, ie. nonincendive techniques
for Div. 2) and must be certified as intrinsically safe.
Atmospheres containing combustible metal dusts,
including aluminum, magnesium and their com- Simple Apparatus
Group E mercial alloys, or other combustible dusts whose Simple apparatus is defined as “a device that will neither generate
particle size, abrasiveness and conductivity present nor store more than 1.5 V, 0.1 A or 25 mW.”
similar hazards in the use of electrical equipment
Examples include switches, thermocouples, LEDs, connectors
Atmospheres containing combustible carbona-
and RTDs. Simple apparatus themselves do not have to be
ceous dusts, including carbon black, charcoal, coal
approved, but must be used with an approved barrier and
or coke dusts that have more than 8 percent total
Group F installed in accordance with the control drawing.
entrapped volatiles, or dusts that have been sen-
sitized by other materials so that they present an Installation Requirements for Intrinsically Safe
explosion hazard and Associated Apparatus
Atmospheres containing combustible dusts not Intrinsically safe and associated electrical equipment or apparatus
Group G included in Group E or Group F, including flour, must be installed subject to the following two conditions:
grain, wood, plastic and chemicals
In the United States and Canada, temperature classifications are All of the protection methods against explosion or the danger of
divided into six classes—T1 through T6. Classes T2, T3 and T4 fire require temperature classification in relation to any surface
are further subdivided, as shown in the following table. that can come in contact with a potentially explosive atmosphere.
Maximum Temperature . North American The Classification of Hazardous Locations for Zones
Degrees C Degrees F Temperature Classification In the United States and Canada, the zone classification method
450 842 T1 is recognized and applied; however, it is generally considered
the secondary method used verses the division method. For
300 572 T2 simplification, we will identify the division method for North
280 536 T2 A America and the zone method for Europe.
260 500 T2 B
In Europe, the tendency is to follow the recommendations of
230 446 T2 C EN 60079-10, based on which any place where the probability
215 419 T2 D of the presence of a flammable gas exists must be classified
200 392 T3 according to the subdivision in one of the following zones:
180 356 T3 A
An area in which an explosive air/gas mixture is
165 329 T3 B Zone 0
continuously present or present for long periods
160 320 T3 C
135 275 T4 An area in which an explosive air/gas mixture is
Zone 1
120 248 T4 A likely to occur in normal operation
100 212 T5 An area in which an explosive air/gas mixture is
85 185 T6 Zone 2 unlikely to occur; but, if it does, only for short
periods of time
Table 2.1
Surface temperature classifications in North America An area in which a combustible dust cloud is part
Zone 20 of the air permanently, over long periods of time
or frequently
Each gas is associated with a temperature class based on its
ignition temperature. It is important to note that there is no An area in which a combustible dust cloud in air
Zone 21
correlation, for any specific mixture, between ignition energy and is likely to occur in normal operation
ignition temperature.
An area in which a combustible dust cloud in air
For example, hydrogen has a minimum ignition energy of 20 µJ Zone 22
may occur briefly or during abnormal operation
and an ignition temperature of 1040°F (560°C), while acetaldehyde
has an ignition energy greater than 180 µJ and an ignition
temperature of 284°F (140°C). Any other plant location that is not classified as a hazardous
location is to be considered a non hazardous location.
Because it is possible for the dangerous mixture to remain inside Sometimes the internal overpressure protection method is the
the enclosure after the pressurization system has been turned only possible solution, i.e., when no other method of protection is
off, it is necessary to expel the remaining gas by circulating a applicable. For example, in the case of large electrical apparatus
certain quantity of protective gas before restarting the electrical or control panels where the dimensions and high-energy levels
equipment. make it impractical to use an explosion-proof enclosure or
the application of the energy limitation method, the internal
The classification of the electrical apparatus must be based on overpressure protection method is often the only answer.
the maximum external surface temperature of the enclosure, or
the maximum surface temperature of the internal circuits that The use of pressurization is limited to the protection of apparatus
are protected with another protection method and that remain that do not contain the source of an inflammable mixture. For
Encapsulation
The encapsulation protection method is based on the segregation
of those electrical parts that can cause the ignition of a dangerous
mixture in the presence of sparks or heating, by potting in resin
that is resistant to the specific ambient conditions. (refer to
Figure 3.3). OIL
Figure 3.7
HAZARDOUS.ATMOSPHERE Schematic of an intrinsically safe circuit
European practice
According to the CENELEC EN 50020 standard, two categories
of intrinsic safety—Ex “ia” and Ex “ib”—are specified, defining the
number of faults allowed for specific classifications and the safety
coefficients to be applied during the design phase.
Figure 3.6
Schematic of increased safety protection method Category “ia” allows up to two independent faults and can be
used for a Zone 0 application, while category “ib” allows only one
fault and can be used for a Zone 1 application.
The increased safety method of protection was developed in
Germany and is recognized in Europe by the CENELEC EN The intrinsic safety method of protection is the only method
60079-7 standard. that protects the apparatus and its relative wiring in hazardous
locations, including the breaking, short-circuiting or accidental
The increased safety technique is suitable for Zones 1 and 2. This grounding of the connecting cable. Installation is greatly simplified
technique can be used for the protection of terminals, electrical because there are no requirements for metal-clad cables, conduits
connections, lamp sockets and squirrel gauge motors, and is or special devices. Also, maintenance and check procedures can
often used in combination with other methods of protection. be carried out by competent personnel, even when the circuit is
According to the standard, the prescribed means of construction being powered and the plant is functioning.
must be made in such a way as to obtain an elevated safety The intrinsic safety method of protection is intended for process
coefficient during normal functioning. In the case of eventual instrumentation applications where the low power required is
allowed overloading, construction must comply to very specific compatible with the energy-limitation concept. In general, when
standards regarding connections, wiring, components, distances
Non incendive and intrinsic safety protection methods are both The following table presents a summary of the protection methods
based on the prevention concept. However, for the non incendive against explosion, stating the functioning principles from both the
approach, the device or circuit is not evaluated for safety under North American and European practices.
fault conditions. As a result, energy surges, equipment faults and
static electricity are not addressed. For this reason, non incendive
devices are not approved for Division 1.
The determination of whether a circuit or system is non incendive
is often left to the user. Many end-users are reluctant to install
equipment classified as non incendive in Division 2 locations
without further protection. As a result, the decision is often made
to employ intrinsic safety as the protection method.
The prescribed methods of construction are similar to the ones
required by the increased safety protection method—specifically,
relating to components, enclosures, connection elements, surface
temperatures, distances, etc.
This technique, due to its nature, is allowed only in Division 2
where the probability of danger is very low. This appears to be a
limiting factor, but it is important to keep in mind that
approximately 80% of the hazardous locations in a plant are
classified as Division 2.
An excellent example in the use of the non incendive, or simplified
protection method, is as follows:
A fieldbus distribution block is located in a Division 2
location and handles instruments also located in a
Division 2 area as well as those in a Division 1 area.
Due to the large number of instrument spurs intended to
be connected/disconnected, the non-incendive method
of protection represents the most rational, effective and
economical solution for the Division 2 instruments while
intrinsic safety provides the best alternative for the
Division 1 field devices, thus a combination of protection
methods best solved the entire application.
Table 3.1
Maintenance Costs
Relative to maintenance costs, intrinsic safety is the most
advantageous because this method allows live maintenance with Figure 4.1
no need for plant shutdown. Intrinsic safety is also more reliable
due to the use of infallible and derated components as prescribed Schematic of an intrinsically safe circuit
by the standards.
Explosion-proof enclosures require that particular attention be In order to affirm than an electrical circuit is intrinsically safe, the
given to the integrity of the coupling joints and cable entrance, parts of the circuit which are able to store energy, i.e., the inductor
which adds to the cost of maintenance over a period of time. and the capacitor, must be considered. When the switch in the
hazardous location is open, the capacitor accumulates energy
For pressurized enclosures, there is an added cost for the that is discharged when the switch closes, thereby causing an
maintenance of the protective gas supply system and its relative electrical spark. In the same way, when the contact is closed, the
piping. inductor stores energy that is released in the form of an electrical
arc when the switch opens. The energy that can be released by
Conclusion the circuit must be lower than the minimum ignition energy (MIE)
From the comparison of the three most widely used protection of the air/gas mixture present in the hazardous location. Safety
methods, it is evident that intrinsic safety, where applicable, is factors are then applied to ensure that the values allowed are well
preferred for safety and reliability reasons. Intrinsic safety is also below that required for ignition.
the most economical for installation and maintenance. A theoretical estimation of an energy inherent to an electrical
The use of intrinsic safety provides the best mix of an affordable circuit is not always possible, especially when the energy provided
system and safety requirements. by the power source is higher, compared to the energy stored
by the reactive components. For this reason, the data normally
used in considering intrinsic safety is presented in the form
Section 4 of the correlation between electrical parameters of the circuit,
The Philosophy of Intrinsic Safety voltage and current, and the minimum ignition energy level of the
hazardous atmosphere.
In the previous section, the different methods that are used
to reduce the danger of explosion or fire were presented. The An electrical circuit, no matter how complex, is sequentially
protection methods, based on the containment and segregation examined as resistive, inductive and capacitive. If the safety
concepts, are methods that contain the explosion in order for criteria are satisfied by the different types of circuits, the circuit
the energy source—electrical or thermal—to avoid coming in can be considered intrinsically safe.
contact with the potentially explosive mixture. In both cases, the
use of appropriate enclosures and specific wiring and installation
Resistive Circuits
systems are required. This section will discuss how the intrinsic
safety method prevents the ignition of the dangerous mixture, A circuit is considered as resistive when the reactive part,
while simplifying the installation and use of the required apparatus inductance and capacitance, is zero or negligible (refer to
that is connected to the electrical circuits directly located in a Figure 4.2)
hazardous location.
Inductive Circuits
An electrical circuit is inductive when the reactive part, due to
its inductance, is high with respect to the resistive part (refer to
Figure 4.4).
Figure 4.2
Schematic of a resistive circuit
HAZARDOUS
The energy released by this type of circuit depends essentially on ATMOSPHERE
R
the power supply source V and the current limitation due to the
presence of resistor R.
The experimental tests on this type of circuit have demonstrated
that the capacity for igniting a dangerous mixture depends on V
the open-circuit voltage (Voc = V) and the short-circuit current
(Isc = V/R).
The ignition curve for resistive circuits is shown in Figure 4.3.
Figure 4.4
mA
I Schematic of an inductive circuit
100 Class.I
Group.D
0
C Voc
V
1
Class.I
Group.C
Figure 4.7
1 A capacitive circuit
0.
Class.I
Groups When the circuit is open, the capacitor charges to a voltage V
0.
A.&.B and accumulates an energy (E = 1/2 C V2) that is released in
the form of a spark at the point where the circuit closes. For an
0.1
10 0 0 100 00 00 1000 I .(mA) analogy with the inductive circuit with an inclination of -2 on the
logarithmic scale, a relationship appears to exist between the
capacitance value and the voltage source. However, experimental
tests have demonstrated that this theoretical relationship does not
Figure 4.5 exist and the ignition curves are as shown in Figure 4.8.
Minimum ignition current for inductive circuits
The curves in the above figure refer to a 24-volt power supply C.+...Ω
C.+.1.Ω
source. Experimental tests have shown that, for inductor values
greater than 1 mH, the minimum ignition current is independent
C. (µF)
from the power source for values up to 24 volts, as illustrated in 100 Minimum igniting
the graph in Figure 4.6. voltages applicable to
1000 Class I, Groups A & B
For a more detailed ignition curve, refer to the Additional electrical apparatus.
Information section. 00
100
0
10 C.+.0.Ω
I 1 0.1.mH
(A)
1.mH 1
0.
C.only
0.1
0.1 10.mH
0.0
100.mH
0.01
1 10 0 100 00 1000
V
0.01
10..V .V 100.V
V Figure 4.8
Minimum ignition voltages for capacitive circuits
Figure 4.6
Minimum ignition current for inductive
circuits in relation to voltage V
European practice
Classification of Intrinsically Safe .
Example 1: [Ex ia] IIC
Electrical Apparatus
(Associated Electrical Apparatus located
The standards relative to intrinsic safety include three types of in a non hazardous location)
apparatus:
Example 2: Exd [ia] IIC T4
• Simple apparatus (Associated Electrical Apparatus in an explosion-proof
• Intrinsically safe electrical apparatus enclosure located in a hazardous location)
• Associated electrical apparatus The marking between [ ] indicates that it is an associated electrical
apparatus.
Simple Apparatus Intrinsically safe electrical apparatus and associated electrical
Simple apparatus include devices in which none of the following apparatus are classified as Class I, II or III. Class I apparatus,
values are exceeded: 1.5 V; 0.1 A; 25 mW. subdivisions A,B, C and D can be associated, relative to the type
of dangerous atmosphere in which the apparatus are to be used
Passive sensors (thermocouples, resistance detectors, contacts, (refer to Section 2, Differences between European and North
light emitting diodes [LEDs], etc.) are part of this category and American Practices).
can be directly placed in hazardous locations. There are no
requirements for certification and labeling. Intrinsically safe electrical apparatus located in hazardous
locations must also be classified according to the maximum
Intrinsically Safe Electrical Apparatus surface temperature (refer to Section 2, Surface Temperature
Classification in North America and Surface Temperature
Intrinsically safe electrical apparatus are electrical devices in
Classification in Europe).
which all of the circuits are intrinsically safe. Field instrumentation
(transmitters, I/P, solenoid valves, etc.) used in hazardous
locations must be certified as intrinsically safe. Certfication Electrical Apparatus Categories for .
is based on the maximum energy level (group of gas) and the Zone Classification
maximum surface temperature.
Intrinsically safe electrical apparatus and the intrinsically safe
A label must be placed on the device that indicates the Approval part of the associated electrical apparatus are divided into two
Type, Class, Division and Group used, and references a specific categories—“ia” and “ib.”
Control Drawing.
• Category “ia”: An electrical apparatus belonging to category
An example of a European label is: Ex ia IIC T4 “ia” must not be able to ignite a dangerous mixture during
normal functioning, during a single-fault condition or during a
Associated Electrical Apparatus combination of a two-fault condition with the following safety
coefficients:
Associated electrical apparatus are electrical devices in which
not all of the circuits are intrinsically safe, and that contain parts 1.5 During normal functioning with one fault
of circuits that can interfere with the safety of the connected 1 With two faults
intrinsically safe circuits.
• Category “ib”: An electrical apparatus belonging to category
Passive barriers, DC isolated barriers and instrumentation
“ib” must not be able to ignite a dangerous mixture during
in general, which are used to interface signals coming from
normal functioning or during a single-fault condition with the
hazardous locations, are part of the category and must be
following safety coefficients:
certified according to the maximum energy level (group of gas)
that can be transferred to the hazardous location. 1.5 During normal functioning with one fault
This apparatus must be placed in a safe area unless the apparatus 1 With one fault, but under the condition that the
are protected with another protection method that is appropriate construction of the apparatus does not contain
for the given explosive atmosphere. any unprotected part that can generate sparks.
Also, the apparatus must not be exposed to a
potentially dangerous atmosphere, and the fault
must be automatically relieved
For Zone 0, where danger is ever present, category “ia” allows Component-dimensioning
up to two nonsequential events. For Zone 1, where danger is
intermittent, the two events are the simultaneous presence of the An intrinsically safe system must remain intrinsically safe even
dangerous gas and a single-fault condition in intrinsically safe during a single- or two-fault condition. Generally, an electrical
apparatus. fault can be caused by the deterioration of the components or by
accidental short circuits.
It is evident that apparatus designed for Zone 0, category “ia,”
can be used in Zones 1 and 2 with a greater margin of safety. The components, upon which intrinsic safety depends must
have a fault mode so as not to decrease the safety degree and
are considered “infallible” when in specific fault conditions. They
Intrinsic Safety in the North American System are not subject to more than 2/3 of their nominal characteristics
In the United States, the competent authority for the classification (power, current or voltage).
of hazardous locations is the National Fire Protection Association The components that do not satisfy these requirements must be
(NFPA). The NFPA is responsible for the National Electrical Code, considered as subject to fault during normal operation.
NFPA 70, and the American standard for intrinsic safety is
ANSI/UL 913 Classification of Hazardous Locations. The following components are considered “infallible”:
Article 500 of the National Electrical Code stipulates the use • Metal film resistors.
of electrical apparatus in hazardous locations and defines the • Wire-wound resistors, if manufactured in such a way that the
classification of the areas, the groups of potentially explosive wire cannot unwind in case of an interruption
material and surface temperatures.
• Electro-mechanical relays and optical isolators, if approved
UL 913 is specifically related to intrinsic safety and is the authority as intrinsically safe components
on which the standards used by the testing labs are based.
• Transformers, both of power supply and signal, if
A hazardous location of Division 1 includes the corresponding manufactured and tested according to the standard. For
Zone 0 and Zone 1. Therefore, only one intrinsic safety category is these components, the functioning condition within 2/3 of
allowed with the following safety factors: their nominal power is not required.
1.5 Considering the most unfavorable condition • Capacitors that are highly reliable and contain at least two in
of a single fault a series. Tantalum and electrolytic capacitors are not allowed.
1 Considering the most unfavorable condition of • Semiconductors, such as diodes and zeners, are used as
two faults voltage limiters and have a fault mode that is generally the
short circuit, thus providing a short to safety ground. The
The North American standard is equivalent to the European eventuality of a fault for interruption is not to be excluded;
standard for category “ia.” therefore, one diode is not sufficient to guarantee an infallible
state. The standard requires at least duplication and, in
The certification of apparatus, as it relates to the present
certain cases, triplication.
danger—gas, dust, fiber—and surface temperature, follows the
same concept as the European classification. The differences Series-connected semiconductors that are used as current
lie with the denomination of the groups and the subclasses of limiters must be at least duplicated and are restricted to
temperature. certain applications.
The ignition curve for the resistive, inductive and capacitive The series-connected diodes that are used to block current
circuits are identical to European standard EN 50020. that otherwise would be circulating in the opposite direction
from that of normal functioning can be used, but triplication
is required by some standard.
Design and Construction Aspects of Intrinsically
Safe Apparatus The “infallible” components of an intrinsically safe circuit must be
highlighted and mounted in such a way as to make it impossible
From an electrical point of view, the design of intrinsically safe
to accidentally be excluded from the circuit. For this purpose,
apparatus must limit the maximum current and maximum voltage
the distances in air and on the surface between the conductive
that can be present in hazardous locations, as a consequence of
parts must be in compliance with a Nationally Recognized
a fault or combination of faults, with values lower than the one
Testing Laboratory (NRTL) standard, such as FM 3610, UL 913 or
derived by the ignition curves after applying the adequate safety
CSA C22.2, No 157.
factor.
Distance through An intrinsically safe circuit can have only one grounded point;
1 1.3 2 2 2 2.6 3.3 4.6 5.3 therefore, the isolation required toward ground has the function
encapsulation (mm)
of minimizing the probability of an eventual second-ground
Table 4.1 connection of the circuit that can introduce a dangerous difference
of potential between the two points, if there is no equipotential.
Over surface distances, through air distances
and distances through encapsulation For functional reasons, in the application where the intrinsically
1
Comparative Tracking Index safe circuit already has a grounded point, i.e., thermocouple with
grounded hot junction, all the remainder of the circuit must be
The “through air distance” is the shortest route in air between the galvanically isolated from all other circuits.
conductive parts, while the “over surface distance” is the shortest
When intrinsically safe and non-intrinsically safe circuits are
route on solid surfaces.
contained in the same apparatus, the required isolation between
Distances that are within 1/3 of the distance shown in the above the circuits must be at least 1500 volts.
table are considered as faults. Distances under this value cause
the conductive parts to be classified as short-circuited. Human Error
In general, the surface distances are greater than the distances Apparatus containing circuits or parts of circuits that are
in air, except in cases where the separation is not sufficiently intrinsically safe require an adequate protection to prevent
extended to be considered effective. possible interferences or errors by installation, maintenance and
inspection personnel. The standard requires a protection against
Figure 4.9 illustrates how to determine surface distances between the input of solids larger than 12 mm for enclosures; connectors,
conductive parts. cables and printed circuit boards cannot be exchanged with
others that are similar inside the apparatus, if a dangerous
a/s
situation would exist as a result.
a
It is obvious that absolute protection is impossible; therefore, it
is necessary to have adequate documentation that includes the
3 mm correct installation, maintenance and control procedures in order
3 mm to minimize errors or interferences by authorized personnel.
s
Figure 4.9
Determination of surface distances between conductive parts
Power Supply
La Maximum allowed external inductance Supply Transformer
Figure 4.11
The efficiency of passive barriers in limiting the maximum energy
to the hazardous location substantially depends on the integrity of Schematic of a galvanically isolated barrier
the barrier ground connection. U.S. installation rules require that
the ground-connection resistance of the barrier must be lower The main difference between a passive barrier and a galvanically
than 1Ω. isolated one, or active barrier, lies in the safety components
that are used to obtain the isolation between the non hazardous
location and the circuit related to intrinsic safety.
Intrinsically safe apparatus never stand alone (unless they are A simple system, as illustrated in Figure 5.1, is easy to evaluate
battery operated). Generally, it is part of a system in which the because the fault combinations are few, and the knowledge of the
certified components are used to guarantee the safety of the apparatus’ safety parameters and the cable characteristics are
system. sufficient to verify the safety of the system.
The simplified schematic of an intrinsically safe system is shown A more complex system (e.g., combinations of barriers or the use
in Figure 5.1. of multiple cables) requires a more detailed analysis because the
fault combinations are numerous and not always obvious.
intrinsic safety and can be designed to limit the energy toward the
hazardous location to the required level. C C C C
Intrinsically safe interfaces (e.g., passive barriers) prevent For a 2-conductor cable, the manufacturer’s data is sufficient. For
the transfer of dangerous energy coming from the uncertified shielded or multiconductor cables, the analysis is more complex.
instrumentation in non hazardous locations. In these cases, it is advisable to: (1) measure the capacitance and
inductance values on a sample cable, using an alternative current-
Figure 5.4
Figure 5.3
Example of an intrinsically safe system and its parameters
Relationship between cable length and stored inductive energy
Ratio L/R, normally specified in µH/Ω, can be an alternative to the 3. Associated apparatus (i.e., passive or active barriers) must
cable inductance value. This value permits more flexibility in cable be certified for the type of hazardous location in which they
installation because it is not bound to the length limit. receive or send signals.
4. The electrical voltage and current parameters of the two
apparatus must be matched, according to the following
relationships:
Voc ≤ Vmax
I sc ≤ I max
Both relationships must be in compliance for safety to be
guaranteed.
5. Verify that the reactive parts of the system—capacitance
and inductance—are within the safety limits, according to
the following relationships:
Ccable ≤ Ca - Ci
Lcable ≤ La - Li
Mains
System
I.S. Passive Non haz.-
D Correct: . Appa- Barrier location
ratus Apparatus
The maximum distance
N.H.L. between the lid and the
H.L separator must be less
than 1.5 mm; or
the separator must
guarantee a distance in
Non Intrinsically Intrinsically air around the lid of at fault current
Safe Safe least 50 mm between Barrier ground < 1Ω
Structural ground
Grounded Metal or the terminals of the
Insulating Partition intrinsically safe circuit
System
and the non intrinsically Ground
safe circuit.
Figure 6.4
Schematic of a grounded passive barrier
Figure 6.3
Examples of wiring in small enclosures
containing associated apparatus
The ground connector must be mechanically and electrically
reliable and be able to reduce the fault current or the sum of
the fault currents, if more barriers are connected to a single-
ground bus.
The connecting cable used in grounding the barriers must be at
least No. 12 AWG (American Wire Gauge).
S1 S2 Apparatus
S3 Pass.
S4
fault current Barr.
Ground Bus
Structural ground System Barrier Ground < 1Ω
Ground
Structural Ground
Figure 6.5
System Ground
Schematic of a ground connector for
a passive barrier (used only in Germany)
Figure 6.6
Example of shield ground connections
The fault current, following the route shown, can increase
the ground potential of the hazardous location circuits in
comparison to the one of the reference ground system. This For functional reasons, the S1 shield is connected to the same
does not represent a dangerous situation because all of the grounding point as the measuring circuit. This must not be
metallic structures in a hazardous location are connected to the connected to the transmitter’s metallic parts in order to prevent
equalization conductor, resulting in an isopotential state. This type the second-circuit ground connection, which is not permitted by
of connection is permitted for Zones 1 and 2 in Germany. For the intrinsic safety protection method.
Zone 0 applications, the use of galvanic separation, independent
from the degree of isolation of the hazardous-location apparatus, Since the purpose of the field transmitter is to galvanically
is mandatory. isolate the thermocouple’s circuit from instrumentation in non
hazardous locations, there must be no connection between
shields S1 and S2.
Grounding of Shielded Cables
Shields S2 and S3 provide the shielding of the connection
The use of shielded cables for connecting the hazardous location between the transmitter and the barrier. They are interconnected
sensors or transmitters with the non hazardous location control in an isolated point of the junction box terminal block.
and measurement apparatus is widespread.
S3 is also connected to the barrier’s ground bus that, by means of
From a functional point of view, the shield’s purpose is to create a separate conductor, is connected to the reference ground point.
an equipotential zone around the conductor’s capacitive coupling
with that of other conductors. This is only true if the shield is Shield S4 completes the shielding of the system and is not very
connected to a grounded reference potential. important from a safety point of view. It is connected to the
shield’s reference point, which is represented by the ground bus.
The shield should be grounded at only one point—preferably, at
the system’s ground point. If the shield is grounded at two non For this type of connection, it is necessary that Shield S2 be
equipotential points, the current could circulate in the shield, properly isolated from the transmitter’s metallic structure;
preventing functionality. Therefore, a shielded cable must be otherwise, a situation as shown in Figure 6.7 can occur.
Adequacy of all the Field Elements 6. They do not have points of the circuit grounded or poorly
isolated toward ground, only if connected with diode safety
Demonstrate that all of the apparatus installed in hazardous barriers without galvanic isolation, with the exception of
locations are free from the risk of fire or explosion by: the equipotential ground connection on the barrier.
(1) verifying that the apparatus are connected with simple
devices (Vmax ≤ 1.2 V; Imax ≤ 0.1 A; Pmax ≤ 25 mW), or (2) verifying 7. The eventual loosening of cable clamps or conductor input
that a protection method is being used that is authorized for the joints does not jeopardize the tightness of the enclosure
specific installation zone and compatible with the gas groups against water and corrosive atmospheric elements.
and temperature class.
Adequacy of all Associated Apparatus
Explosion-proof apparatus
For the adequacy of the associated apparatus, verify that:
Specifically, for explosion-proof apparatus, verify that:
1. They have been exclusively installed in a protected non
1. All of the apparatus are installed in Division 2, or Division 1
hazardous location, unless other protection methods that
with certain restrictions. (In Europe Zone 1 or Zone 2; Zone
are suitable for the hazardous location have been used.
0 does not permit the installation of electrical apparatus
using only the explosion-proof protection method.) 2. The type of certification is compatible with the intrinsically
safe circuit to which they are connected, according to the
❷2. Certification is compatible with the gas group and surface
hazardous location and the gas group.
temperature class of the flammable mixture present.
3. They have safety parameters that are compatible with both
3. None of the explosion-proof points have been damaged
the connection cable and the intrinsically safe apparatus to
during transport or installation.
which they are connected.
4. All of the openings toward the outside of the enclosure
4. Separation and identification of the intrinsically safe circuit
have been used (flame break joint, conduit [pipe] joint) or
exists along the entire connection route, as required by the
properly sealed with explosion-proof caps that are properly
standards.
tightened.
5. They have correctly rated and installed internal fuses and
❺5. All of the removable lids are integral, closed and tight
that an external protection device (i.e., isolator breaker) is
(lid bolts all present and tight; screw-type lids tightened
present on the main power line.
completely and equipped with devices against accidental
unscrewing).
Agreement between the Safety Parameters and the
6. All of the threaded junctions are integral and protected
Associated Apparatus
against corrosion.
Any apparatus that is certified or recognized as safe can become
7. Each enclosure has an external ground connection
unsafe if they are used in connection with other apparatus,
properly tightened and efficient.
even if these apparatus are certified as safe. Therefore, use the
Intrinsically safe passive barriers use zener diodes to limit the 1. No requirement of an isopotential ground system due to
voltage to the hazardous (classified) location and fused “infallible” input/output galvanic separation
resistors to limit the current. 2. The use of non isolated field elements permitted
An equipotential ground system, separated from the plant ground 3. Electrovalve drivers always safe, even during the
and safely connected to a single ground point, must be present in fluctuations of the coil resistance due to ambient
order to use zener barriers. temperature variations
The resistance of the intrinsically safe circuit’s ground connection 4. Short-circuit protection
must be lower than 1Ω (refer to Figure 6.6). 5. Insertion or removal from the loop without turning off
If an equipotential ground system is not available, zener barriers power.
cannot be used.
Limitations: Loop-powered Isolated Barriers
Hazardous-location devices, such as thermocouples, resistance
1. Higher internal voltage drops than with passive barriers
temperature detectors (RTDs), transmitters, contacts,
electropneumatic converters, electrovalves, etc., must be isolated 2. Higher cost than that of passive barriers
from ground (at least 500 Vac ), or these devices cannot be used.
hazardous location and the non intrinsically safe circuits that are YES NO
located in a non hazardous location.
Barriers of this type require neither isolated sensors nor an Distance is less Distance is less
isopotential ground system. than 300 m.*? than 300 m.*?
For the plug-in version, these barriers can be inserted or removed YES NO
while the power is on. This allows repairs to be made quickly
without compromising the intrinsic safety of the system. Non-isolated
Passive Barrier Barriers for Transmitters Intrinsically Safe Isolated
(Dual AC Channel) + TC/mA (see specific diagram) Converters
Without exception, powered isolated barriers are technically Uncertified Converter
suitable for all of the intrinsic safety applications. *This distance must be verified for each particular application.
1. No requirement of an isopotential ground system due to Choice criteria for thermocouple detector barriers
input/output galvanic separation
2. The use of non isolated field elements permitted
3. High-voltage signal levels available in the field,
Resistance Temperature Detector
independent of voltage supply Barriers (ANALOG INPUT)
4. Short-circuit protection
Are RTDs isolated
5. Provide a standardized high-level isolated output signal (500 V) from
Recommended
Solution
ground?
(usually 4-20 mA)
YES NO
6. For the plug-in version, quick substitution possible without
shutting down the power supply
Distance is less Distance is less
7. Suitable for all intrinsically safe applications, without than 500 m.*? than 500 m.*?
exception
YES NO NO YES
YES NO
YES NO
Non isolated
Passive Barrier Barriers for Transmitters Intrinsically Safe Isolated
(Dual AC Channel) + TC/mA (see specific diagram)
Uncertified Converter Converters
Figure 8.2
Choice criteria for resistance temperature detector barriers
Are transmitters
Recommended Are contacts
isolated (500 V)
Solution Recommended
from ground? isolated (500V) Solution
from groud?
YES NO
YES NO
Isopotential ground
Isopotential ground
system is available
system available
and acceptable?
and acceptable?
YES NO YES NO
YES NO
NO YES
Voltage available
to transmitter Voltage available to
and load OK? transmitter and load
OK?
YES NO YES NO
Recommended
Solution
Recommended
Load > 250Ω Solution
NO YES
Isopotential ground
system available
and acceptable?
YES NO
Isopotential ground
system available
and acceptable?
YES NO
Hazardous.Location Non.Hazardous.Location
Hazardous.Location Non.Hazardous.Location
Thermocouple Intrinsic Safety Barrier
Isolated 500 V Thermocouple Intrinsic Safety Barrier
From Ground. (Grounded or
Power Supply Poorly Isolated)
Recommended
Solution
Recommended Power Supply
Solution
4-20 mA
4-20 mA
Powered Isolated (T.C./mA)
Powered Isolated
(Converter T.C./mA)
Power Supply
4-20
mA Tx
Isolated I.S. Tx V Supply
Passive Converter
Non Isolated T. C./mA 4-20 mA
4-20 mA
4-20 mA
Power Supply
Recommended
Isolated & Non Isolated I.S. Tx Solution Powered Isolated
(Barrier for Transmitters)
4-20 mA
Powered Isolated
(Barrier for transmitters)
Hazardous.Location Non.Hazardous.Location
Hazardous.Location Non.Hazardous.Location
RTD - Platinum 100 Intrinsic Safety Barrier
Isolated 500 V RTD - Platinum 100 Intrinsic Safety Barrier
from Ground Grounded or
Poorly Isolated
Power Supply
Recommended
Solution Power Supply
Recommended
Solution
4-20 mA
4-20 mA
Powered Isolated
(Converter I.S. R TD/mA)
Powered Isolated
(Converter T.C./mA)
Converter
Passive (RTD/mA) 4-20 mA
Non Isolated
4-20 mA
4-20 mA
Loop Powered Isolated
Powered Isolated
(Barrier for Transmitters)
Power Supply
Recommended
Isolated & Non Isolated I.S. Tx Solution
4-20 mA
Powered Isolated
(Barrier for Transmitters)
Hazardous.Location Non.Hazardous.Location
Hazardous.Location Non.Hazardous.Location Contact / Proximitor Intrinsic Safety Barrier
Transmitter Intrinsic Safety Barrier
Isolated 500 V Recommended Power Supply
From Ground Solution
4-20 mA
Power Supply
Powered Isolated
Output
Contact
Relay
Power Supply
4-20 mA
Figure 8.13
Passive Non Isolated
Application examples for contacts/proximitors
Power Supply
Hazardous.Location Non.Hazardous.Location
Electropneumatic Converter Intrinsic Safety Barrier
Power Supply
4-20 mA
Recommended
Solution
Loop Powered Isolated
I 4-20 mA
P IN
Powered
Figure 8.11
Application examples for transmitters I 4-20 mA
isolated 500 V from ground P IN
I 4-20 mA
Hazardous.Location Non.Hazardous.Location P IN
Power Supply
Hazardous.Location Non.Hazardous.Location
4-20 mA Solenoid Valve Intrinsic Safety Barrier
Isolated from ground 500V
Loop Powered Isolated Recommended Power Supply
Solution
Command
Command +
25-35 V
-
Figure 8.15
Application examples for solenoid valves
Section 9 Hazardous..
Area
Safe.Area,.Div..or.Zone. Product info. on
pgs. 301, 309
Practical Solutions Z787.*
Safe
Intrinsic safety barriers are the core of Pepperl+Fuchs product Plus
portfolio. We offer the widest selection of products for protection
of electrical signals located in hazardous (explosive) areas. This
guide presents common hazardous area applications involving
intrinsic safety barriers to assist in selecting the correct barrier for
your application.
By far, our most popular intrinsic safety barrier is the flexible,
DIN rail mounted K-System isolator. This product line consists
of over 150 different functional designs to meet the demands of
today’s factory and process automation industries. The unique Figure 9.1
design allows simple expansion with no additional wires, and can
be easily designed for several redundant power configurations. This illustrates an alternate method of providing mutlitple channels
K-System components meet SIL IEC61508 ratings to ensure in a “quasi-floating” configuration. The first channel of the Z787.*
conformity to international safety standards for systems and (or Z787.H.*) is used as the field power supply while each diode
processes. return channel is isolated from ground.
Zener diode barriers are the most economical hardware method
Hazardous.. Safe.Area,.Div..or.Zone.
available to solve a hazardous area barrier/intrinsic safety Product info. on
Area pgs. 300, 301, 309
application. Our SafeSnap series of zener barriers has over Z787.*
Z787.H.*
85 unique versions to solve your intrinsic safety application. Safe
SafeSnapPlus barriers contain a removable fuse that eliminates Plus
disassembly, disconnection of wiring or disposal of an entire
barrier in the event of a fault.
In addition to the intrinsic safety barriers presented in this
application guide, Pepperl+Fuchs also offers HiD2000, our line of
backplane mounted isolated barriers. This innovative product is
ideal for applications requiring tight DCS or system integration.
The powerful motherboard system is available in a wide range
of termination assembly versions that can be installed easily.
The intrinsic safety modules simply plug into the motherboard,
Z786
so wiring is never an issue on the barrier itself. Plus, HART
multiplexers can be integrated easily into a HiD2000 system once
the proper module is installed on the motherboard.
Also available is our μZ range of zener diode barriers that
combines outstanding features and performance in a compact
housing. Its thin width and low profile—the lowest profile zener
on the market—make it perfect for those hard-to-reach areas of
a cabinet or an enclosure. Plus, μZ comes with many of the great
features found in our full line SafeSnap product.
At Pepperl+Fuchs, we build and support quality products that
Figure 9.1
meet the demands of our customers and take intrinsic safety
well into the 21st century. Note: SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
barriers have internal fuses.
Switches and NAMUR Sensors
Safe Area or Div 2 Product info. on Hazardous Area Safe Area, Div 2 or Zone 2 Product info.
Hazardous Area pgs. 109, 110 on pg. 108
KFD2-SR2-Ex1.W
KFA5-SR2-Ex1.W
KFA6-SR2-Ex1.W
Input 1
}
Input 1
}
1 8
1 8 R2 Relay
R2 Relay 2 7
2 7 Output
Output R1 R1
R1 R1 3 9
3 9
LB/SC LB/SC LB
LB/SC LB/SC LB
14
15 } Supply
120 VAC
14 (+)
15 (–) } Supply
24 VDC
240 VAC
Collective Error Messaging
Power Rail Connection
Figure 9.3
Figure 9.7
}
KFA6-SR2-Ex1.W.LB
}
1 8
1 8 R2
R2 Relay Relay
2 7 Output 1
2 7 Output 1 R1 R1
R1 R1 3 9
3 9
} }
LB/SC LB/SC LB 11
LB/SC LB/SC LB 11 Relay
Relay Output 2
10 10
Output 2 Signal or Error
Signal or Error 12
12
14
15 } Supply
120 VAC
14 (+)
15 (–) } Supply
24 VDC
240 VAC
Collective Error Messaging
Power Rail Connection
Dual Channel AC
Product info.
Hazardous Area Safe Area, Div 2 or Zone 2 on pg. 119
Hazardous Area Product info. on KFD2-ST2-Ex1.LB
Safe Area or Div 2 pgs. 115, 116 Input 1
Input 1 KFA5-SR2-Ex2.W 4
KFA6-SR2-Ex2.W R2
}
1 8 5 Active Transistor
7
R2 Relay R1 R1 Output 1
2 7 6
Output 1
R1 R1 Active Transistor
3 9 LB/SC LB/SC LB
Output 2 Signal
}
9 or Error
Input 2 11
R2
4
5
10
12
Relay
Output 2
14 (+)
15 (–) } Supply
24 VDC
}
R1 R1 14
6 Supply
Collective Error Messaging
LB/SC 15 120 VAC
LB/SC LB Power Rail Connection
240 VAC
Figure 9.10
Figure 9.5
Product info.
Product info. on Hazardous Area Safe Area, Div 2 or Zone 2 on pg. 121
Hazardous Area Safe Area or Div 2
pgs. 125, 126
KFA5-SOT2-Ex2 KFD2-SOT2-Ex1.LB
Input 1
Input 1 KFA6-SOT2-Ex2
}
7
1 Passive Transistor
1
}
7 R2
R2 Output 1
Passive Transistor 2
}
2 Output 1 R1 R1 8 (+/-)
Passive Transistor
R1 R1 3
}
3 8 Output 2 Signal or
Passive Transistor LB/SC LB/SC LB 9 Error
Input 2 Output 2
9
4
R2
R1 R1
5 14
} Supply
14 (+)
15 (–) } Supply
24 VDC
15 120 VAC
6 240 VAC
LB/SC LB/SC LB Collective Error Messaging
Power Rail Connection
Figure 9.11
Figure 9.6
Hazardous Area Safe Area, Div 2 or Zone 2 Product info. Safe Area or Div 2 Product info.
on pg. 114 Hazardous Area on pg. 124
Input 1 KFD2-SR2-Ex2.W KFD2-SOT2-Ex2.IO
Input 1
}
1 8
}
R2 Relay 1 7 Passive Transistor
2 7 R2
Output 1 8 Output 1
2
R1 R1 9
3
}
R1 R1
10
}
3 Passive Transistor
Input 2 11 Output 2
11
Relay Input 2
4 10
R2 Output 2 4
5 12 R2
R1 R1
6 14 (+)
15 (–) } Supply
24 VDC
R1 R1
5
6
14 (+)
15 (–) } Supply
24 VAC
LB/SC LB/SC LB
LB/SC LB/SC LB
Quad Channel DC
Product info.
Hazardous Area Safe Area, Div 2 or Zone 2 on pg. 117
Hazardous Area Safe Area or Div 2 Product info.
Input 1
on pg. 118
KFD2-SR2-Ex2.2S
Input 2 Input 1
(–) 1 1 (–) 1 KFD2-SRA-Ex4
}
(–)
1 7
Output 1
Channel 1 R2
R2 1 7
2
8
Channel 2
(+) (–)
(+) R1 (+) 2
8
} Channel 1
R1 R1
9 (–) 3 3 (+) 2 2
} Channel 2
}
(–) 9
3 10 R2
Output 2
10
Input 2 11
Channel 1 (+)
(+)
R1
(–) 3 3
11
} Channel 3
Channel 2
12 } Channel 4
Input 4 Input 3
(–) 4 4
4 (–)
(–) 4 12
R2 R2
4
(+) (–)
5 (+) 5
}
(+) R1
R1 5
R1 14 (+) (–) 6 6
6 Supply (+) 5
}
(–)
24 VDC R2 6 14 (+) Supply
LB/SC LB/SC LB 15 (–) (+) 24 VDC
(+)
R1 (–) 6 15 (–)
2:1 Wire LB/SC 2:1 Wire LB/SC
Collective Error Messaging
R1= 400Ω- 2KΩ R2= 10KΩ Collective Error Messaging
Power Rail Connection
Power Rail Connection
6
14 (+)
15 (–) } Supply
24 VAC
LB/SC LB/SC LB
Collective Error Messaging Hazardous.. Safe.Area,.Div..or.Zone. Product info. on
Power Rail Connection
Area Z787.*
pgs. 301, 309
Figure 9.14
Safe
Replaceable
Plus Fuse
I/O
1 Resistor Fuse 8 +27 Vmax
Z-Diodes
Product info. 4-20 mA 2 7 0V
Hazardous Area Safe Area, Div 2 or Zone 2 on pg. 120
Load
Replaceable
3 Fuse 6
Input 1
KFD2-ST2-Ex2
Z-Diodes
1 4 5
R2 Resistor Diodes Fuse
2 Active Transistor
7
R1 R1 Output 1
3
IS Ground
Input 2
Active Transistor
4 9
Output 2
R2
5 Figure 9.18
LB/SC LB/SC
R1
LB
R1
6
14 (+)
15 (–) } Supply
24 VDC
Figure 9.15
12
Hazardous... Safe.Area,.Div..or.Zone. Product info. on (+) 4 11 (+)
Area pgs. 299, 307
Z728.* (–) 6 10 (–) Load
Safe
Replaceable 14 (+)
Plus Fuse 15 (–) 24 VDC
I/O
1 Resistor Fuse 8 Load +27 Vmax
4-20 mA Z-Diodes Power Rail Connection
2 7
0V
Figure 9.22
If the I/O system requires a 1-5 V input, the Z788.R contains a Hazardous... Safe.Area,.Div..or.Zone. Product info.
on pg. 151
Area
precision 250 Ω resistor internally connected between Terminals 3 KFD2-STC4-Ex1
and 4 to facilitate the 1-5 V output from a 4-20 mA transmitter.
9
Hazardous.. Safe.Area,.Div..or.Zone. Product info.
on pg. 301 (+) 1 8
Area
Z788.R 2
S
7 4-20mA
4-20 mA 3
I/O 14 +
Resistor Fuse
1 8 +27 Vmax
15
Z-Diodes
4-20 mA 2 7 V 0V
Power.Rail.Connection
3 6
4
Z-Diodes
5
Figure 9.23
Resistor Fuse
Figure 9.21
This figure shows a galvanically isolated transmitter power
Note: If additional voltage is required for the transmitter, the Z788.R.H can supply similar to Figure 9.23, except the safe area output sinks
provide the necessary increase. The entity parameters must, however, be the current from the I/O device. This barrier is suitable for SIL 2
verified. applications according to IEC 61508.
provides 3-way isolation between power, input and output for (+) 1 8
20-30 V
within a hazardous area and transfers the anlog 4-20 mA signal 4-20 mA 3
from the hazardous to the safe area. These barriers are suitable 14 +
Power.Rail.Connection
Figure 9.24
9 I/O
8 (+)
Load IS Ground
(+) 1 7 (–)
2 12 Figure 9.27
11 (+) Load
4-20 mA 3
10 (–)
Note: When using zener barriers with SMART Transmitters, the over-all
14 (+)
24 VDC resistance for the loop must be considered to ensure correct operation.
15 (–)
SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
Power Rail Connection
barriers have internal fuses.
Figure 9.25
Figure 9.26
Power Rail Connection
Figure 9.28
The figure below shows an alternate method of achieving Note: Depending on calibrator design, connection can be made across
bidirectional SMART communication through a zener diode Terminals 9 and 10 in the safe area.
barrier. The circuit implementing the Z728.* zener barrier must
be individually isolated from each I/O channel or must have the
measurement load attached to the positive leg of the supply for
proper analog/digital communication to occur.
Product info. on
Hazardous... Safe.Area,.Div..or.Zone. pgs. 299, 307
Power.Rail.Connection
Area
Figure 9.30 Z728.*
Safe
Note: The KFD2-STC4-Ex1.20-Y112669 has sink mode outputs. Plus
Replaceable
Fuse
1 Resistor Fuse 8
Z-Diodes
2 7
Hazardous Safe Area, Div 2 or Zone 2 Product info. on
pgs. 155, 156
Area KFD2-STC4-Ex2
KFD2-STC4-Ex2-Y72195
Transmitter I /O
9
(+) 1 8 (+)
Load
(–) 3 7 (–)
IS Ground
12
(+) 4 11 (+) Figure 9.33
(–) 6 10 (–) Load
Note: In order to conserve DIN rail space, the dual channel Z779.* could
14 (+) provide operation and protection for two I/P converters if the Z728.* is
15 (–) 24 VDC
acceptable.
Power Rail Connection
Figure 9.31 A dual channel Z787.* can be used in situations where the return
line of the I/P cannot be connected to the earth ground. The
Note: The KFD2-STC4-Ex2-Y72195 has sink mode outputs
additional diode-return channel of the Z787.* provides isolation for
the 4-20 mA current.
Load
Plus Fuse
Figure 9.34
Note: The KFD2-STC4-Ex1.20-Y112668 has sink mode outputs.
Note: SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
barriers have internal fuses.
Isolated Barriers
Isolated Current/Voltage Driver
The KFD2-CD-Ex1.32 driver barrier features high accuracy and
temperature stability. By special order both the input and output
of this galvanically isolated barrier can be altered to suit the
application. They can be independently configured for either
voltage or current. This module provides 3-way isolation between
power, input and output for superior signal integrity. This barrier is
suitable for SIL 2 applications according to IEC 61508.
I
Source
250 Ω
Isolated Current Driver 12
(+) 4 11 (+)
The loop powered KFD0-CS-Ex1.51P barrier is galvanically 4-20 mA (–) 5 10 (–)
Current
I
Source
isolated making its application very simple. Although primarily 14 (+)
24 VDC
designed for fire detector applications where accuracy is much 15 (–)
less important, it is usually accurate enough for I/Ps. The accuracy Collective Error Messaging
Power Rail Connection
of the KFD0-CS-Ex1.51P is ≤200 µA. This barrier is suitable for
SIL 2 applications according to IEC 61508. Figure 9.38
Product info.
Safe Area, Div 2 or Zone 2 on pg. 192
Hazardous
KFD0-CS-Ex1.51P I/O
Area
(+) 1 11 (+)
1 Resistor Fuse 8
designed to control I/P converters in a hazardous location. It also Z-Diodes
provides lead breakage and short circuit monitoring. This barrier is 2 7
Source
(–) 2
14 (+)
24 VDC
15 (-)
Figure 9.37
I
Source
Hazardous.. Safe.Area,.Div..or.Zone. pgs. 301, 309
Area 250 Ω
Z787.* 12
(+) 4 11 (+)
Safe Current
Replaceable 4-20 mA (–)5 10 (–)
I
Source
Plus Fuse
14 (+)
1 Resistor Fuse 8 24 VDC
15 (–)
Z-Diodes
2 7
Collective Error Messaging
Power Rail Connection
Replaceable
3 Fuse 6
Z-Diodes Figure 9.43
4 5
Resistor Diodes Fuse
IS Ground Thermocouples
Figure 9.41
Zener Diode Barriers
Note: When using zener barriers with SMART I/P field devices, the over-all
resistance for the loop must be considered to ensure correct operation. This is most common method of connecting a thermocouple to
SafeSnapPlus zener barriers are designed with replaceable fuses which a zener diode barrier. The dual channel configuration provides
is denoted by an “F” at the end of the model number. SafeSnap zener a balanced circuit with a maximum of 64 Ω in each channel,
barriers have internal fuses. allowing operation for any thermocouple type.
Resistor
integrity. This intrinsic safety barrier is designed to control SMART 1 8
IS Ground
Source
(–) 2
14 (+)
Isolated Loop Powered Thermocouple Transmitter
24 VDC
15 (-) The loop powered KFD0-TT-Ex1 barrier is galvanically isolated
Collective Error Messaging
and provides a 4-20 mA output for multiple thermocouple inputs.
Power Rail Connection This barrier can be configured manually for the thermocouple type
and upscale or downscale burnout and is also provided with zero
Figure 9.42
and span point potentiometers.
Dual Channel Isolated SMART Current Driver Hazardous Safe Area, Div 2 or Zone 2 Product info.
on pg. 203
Area KFD0-TT-Ex1
The KFD2-SCD2-Ex2.LK is a dual channel SMART current driver
barrier, and which provides 3 way isolation between power,
input and output. The isolator is designed to control SMART I/P I/O
Figure 9.45
(+) 4
(–) 5
V
0 - ±50mV
Measurement
3-wire
S
1 8
x3
2 x3 7
x3
3 x3 6
x3
4 x3 5
Power Rail Connection
Figure 9.46
IS Ground
Resistor Fuse
8 (+) 1 8
(+) 4
Z-Diodes x3
(+) 3 7 (–) 2
Load x3 7
(–) 2
(+) 1 3 6
RxD Programming x3
TxD Z-Diodes
Jack x3
GND 4 5
Resistor Fuse Replaceable
Fuse
11 (+)
24 VDC IS Ground
12 (–)
3 6
Z-Diodes x3
x3
4 5
Resistor Fuse Replaceable
Fuse
IS Ground
Figure 9.49
Note: SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
barriers have internal fuses.
12-35 VDC 1
RxD Programming
1 TxD
Load (–) 2 GND
Jack
(–) 2 8 (–)
4-20 mA
11 (+)
24 VDC
12 (–)
Figure 9.52
I /O
(+) 4 12 (–)
3 11 (–)
1
10 (+)
2
(–) 5 9 (+)
7 (+) RTD Input
24 VDC
8 (–)
Figure 9.51
350 Ω
3 6
Z-Diodes
4 5
Resistor Fuse Vibration Monitoring
IS Ground
Zener Diode Barriers
Z961.* This figure illustrates an example of a zener diode barrier and a
Safe vibration monitor in the hazardous area. The vibration monitor
Plus
Replaceable
Fuse outputs a voltage signal, which is referenced to the positive
1
Resistor Fuse
8 supply, proportional to the vibration waveform at frequencies up
2
Z-Diodes x3
x3 7
to 4 kHz. Therefore, a negative polarity barrier is required and the
positive side of the power supply must be grounded.
3 6
Z-Diodes x3
x3
4 5
Safe Area, Div 2 or Zone 2 Product info.
Resistor Fuse Replaceable Hazardous on pg. 300
Fuse
Area Z896
IS Ground
S
Figure 9.53 1 Resistor Fuse 8
Z-Diodes
2 7
Note: SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener 3 6
barriers have internal fuses. Z-Diodes
4 5
Resistor Fuse
IS Ground
Figure 9.55
Hazardous Safe Area, Div 2 or Zone 2 Safe Area, Div 2 or Zone 2 Product info. on
Product info. Hazardous pgs. 305, 310
Area on pg. 172
KFD2-VR4-Ex1.26 Area Z960.*
I /O Safe
Replaceable
(+) 4 8 (+) Plus
Commmon Fuse
Hazardous Safe Area or Div 2 Product info. Safe Area, Div 2 or Zone 2 Product info. on
Area on pg. 171 Hazardous pgs. 303, 311
KFD2-VR-Ex1.19-Y109129 Area Z961.*
Safe
I /O Replaceable
Plus Fuse
Resistor Fuse
(+) 4 7 (–) 1 8
Z-Diodes x3
V 2 x3 7
(–) 5 8 (+) 0…±10V
Measurement 3 6
Z-Diodes x3
11 (+) x3
24 VDC 4 5
12 (–) Resistor Fuse Replaceable
Fuse
Figure 9.57
Z961.*
Safe
Replaceable
Plus Fuse
Resistor Fuse
1 8
Z-Diodes x3
2 x3 7
3 6
Z-Diodes x3
x3
4 5
Resistor Fuse Replaceable
Fuse
IS Ground
Figure 9.59
Note: SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
barriers have internal fuses.
1 Resistor Fuse 8
Figure 9.60 Z-Diodes
2 7
Replaceable
3 Fuse 6
Isolated Potentiometer Transmitter – Voltage Z-Diodes
4 5
The KFD2-PT2-Ex1, KFD2-PT2-Ex1-1, KFD2-PT2-Ex1-2 and Resistor Diodes Fuse
I/O
(–) 5 8 (+) Isolated Barriers
(–) 4
(+) 3 7 (–)
V Voltage
Measurement Isolated Loop Powered Discrete Output Driver
(+) 2
(+) 1 The loop powered KFD0-CS-Ex1.51P barrier is a galvanically
11 (+)
24 VDC
isolated discrete output barrier. It can be used to energize certain
12 (–) types of solenoids, LEDs and alarms. With a 24 V source, this
barrier will supply approximately 27 mA at 12 V to the hazardous
Power Rail Connection
area field instrument. This barrier is suitable for SIL 2 applications
Figure 9.61 according to IEC 61508.
Supply
24 VDC
Note: KFD2-SL2-Ex2.B is the basic unit and does not include such features as
Isolated Logic Input Solenoid Driver LB/SC monitoring or collective error massaging.
I /O
Hazardous Safe Area, Div 2 or Zone 2 Product info.
(+) 1 7 (+) on pg. 142
Area KFD2-SL2-Ex1.LK
Logic
(–) 2 8 (+/–) Input
(–) 3
I/O
Supply (+) 1
24 VDC
(–) 2 Logic
Input
Collective Error Messaging
(–) 3 Fault
Power Rail Connection
Output
Figure 9.68
S (+) 4
0 - ±500mV
1 Resistor Fuse
8 (–) 5 V Measurement
Z-Diodes
2 7
3 6
Z-Diodes
4 5
Resistor Fuse Power Rail Connection
Figure 9.71
IS Ground
11 (+)
Replaceable 24 VDC
3 Fuse 6 12 (–)
Z-Diodes
4 5
Resistor Diodes Fuse Power Rail Connection
Figure 9.72
IS Ground
Power.Rail.Connection Power.Rail.Connection
Figure 9.73
Figure 9.74
Note: For AC Powered units ask for KFA5-DWB-Ex1.D (120 VAC) or KFA6-
DWB-Ex1.D (240 VAC). Collective error messaging and Power Rail Isolated Rotation Direction Indicator and
connection are not available on the AC units.
Synchronization Monitor
The galvanically isolated KFD2-UFT-Ex2.D comes with a
display for easy on site programming and is used when a
Isolated TimeDelay Relay rotation direction indicator or synchronization monitor is
The galvanically isolated KFD2-DU-Ex1.D comes with a needed. A non-display unit is available with the KFD2-UFT-Ex2.
display for easy on site programming and is commonly used in
applications requiring on delay, off-delay, one-shot or pulsating Hazardous Area Safe Area or Div 2 Product info.
signal conditioning. KFD2-UFT-Ex2.D on pg. 224
(+) 1 11
10 Output 1
RxD Programming 12
TxD
Safe Area, Div 2 or Zone 2 Product info. GND
Jack 17
Hazardous Area on pg. 213
16
18
Output 2
}
Hazardous Area on pg. 226
(+) 1
8
Input for KFD2-GU-Ex1
voltage supply 0-10 V 7 Output 1
(–) 2 2-10 V RxD
(+) 6
Input for 1 TxD
Programming
8
(–) 3
9
0-20 mA Jack
current supply GND
}
4-20 mA 2 7 Output 1 (+) 4
11
Input for (–) 2 (+) 5
9
thermocouples
3 10 Output 2
Cold junction 11
compensation 4 (–) 6 12
K-CJC
10 Output 2
3-wire
5
6
12 14
15 } Supply
120VAC
Figure 9.78
7
0/4-20mA Output 3
(+) 1 (+) 1 8
11
2 2
10 Output 1
12
I
3 3 3 17
RxD 16 Output 2
TxD Programming
GND Jack 18
23
Supply
24 24 VDC
Figure 9.80
Power
24VDC 24VDC
Distribution 7 7
12 12
Power Feed with
12 11 11
Module Power Rail 10 10
24VDC 11
Figure 9.83
Note: PR-03 is a 500 mm insert for standard 35mm DIN Rail. UPR-03 is sold in Fault Signal Output Fault Signal Output
2 meter lengths and comes with its own 35 mm DIN Rail.
Figure 9.85
Fault Signal
7 24VDC 1 3
12 GND
2
10 11 L1 N 4 6
120/240VAC 24VDC
Figure 9.86
Fault Signal Output
Note: The number of isolators per power supply depends upon the power
Figure 9.84 consumption of each module.
Power Supply C
D
G E
125 mm
A - Cover
B - Two leads for power
14 120/240VAC
15 C - One conductor for collective error (UPR-03)
Figure 9.87 Three conductors for bus connection (UPR-05)
Note: The number of isolators per power supply depends upon the power
D - Universal Power Rail
consumption of each module. E - Mounting Holes
F - DIN Rail
G - End Cap UPR-E
Power Rail
A Note: The UPR-03 nd UPR-05 is two meters in length and comes with its own
PR-03/PR-05 35 mm DIN rail.
B
D
Note: PR-03 and PR-05 is a 500 mm insert for standard 35 mm DIN rail.
Individual sections can be connected with a VE-PR link.
Reduction of Risk
The risk analysis provides the value SIL1 to SIL4. The greater the PFD1 PFD2 PFD3 PFD4 PFD5
risk, more precautions must be taken to reduce the risk and more
10% 10%
reliable components must be used. Signal path Signal path
The counter-weight to the potential danger are all the Notes on Equipment Selection
organizational and technical measures taken to reduce the risk. The standards contain no recommended values for the failure
distribution within the instrumentation circuit. The distribution
is determined by the user through selection of the respective
components. The user merely has to keep within the 100 % limit.
Since the sensors and actuators are installed in the field, they
are subject to chemical and physical loading (Process medium,
Tproof pressure, temperature, vibration, etc.); therefore, the failure risk
PFD HFT SFF of these components is correspondingly high. We recommend
the overall PFD be divided between the individual components
as follows: 25% for the sensor, 40% for the actuator, 15% for the
Where Can You Find the Necessary SIL Value? The Optional Safety Classifications SIL1 to SIL4:
What Should be Noted?
Our SIL ratings can be downloaded from the Internet free-
of-charge, either as the full version (15 to 20 pages), or as a As a rule, all Pepperl+Fuchs devices with a SIL rating can be used
management summary (2 pages) at www.am.pepperl-fuchs.com directly as standard types in SIL2 applications.
under the appropriate data sheet page.
To this end, a simple evaluation structure (e. g. 1oo1) is adequate
All Pepperl+Fuchs devices with a SIL rating are from our standard to achieve the customary industrial cycles for function checks
product offering. (i.e. annual intervals).
The functional reliability of the complete risk-
reducing measure is always expressed with
the SIL grading; therefore, all the components
that contribute to this measure must be given
Attention consideration.
Analog
Transmitter
1oo1
IN signal processing
Devices for Applications in the Safety Grading SIL3 area to a safe area. The proximity sensor or switch controls
a form C relay contact for the safe area load. The barrier
output changes state when the input signal changes state.
Zone 2
Exida
TÜV 99 ATEX 1493X,
P+F 02/4-12 R007
II 3 G EEx nAC IIC T4
MECHANICAL
The normal output state can be reversed through the mode
of operation switch S1. Housing Type C see page 454
Redundant evaluation structure (SIL2 and SIL3 with the For a mechanical contact, LB monitoring can be selected
by placing a 10 k7 resistor across the mechanical contact
Dimensions
Weight
4.65" x 0.79" x 4.53" (118 x 20 x 115 mm)
5.3 oz. (z 150 g)
a hardware fault tolerance of 1 (HFT = 1). The failure of a device deenergized state. LB/SC monitoring can be disabled with
S3 in position II. If used in conjunction with P+F's Power
Accessories (page 443)
Power Supplies (page 401)
Connection Diagram
Front View Class I; Div 1, 2
Zone 0, 1, 2
Analog
Removable terminal
Housing type C blue
(see system description)
Hazardous Area Safe Area, Div 2 or Zone 2
Transmitter
1oo2
LED yellow: LED green:
Transmitter
R1 R1
3 9
Switch S2 Switch S3 LB/SC LB/SC LB
(no functions) (LB/SC-monitoring)
IN 14 (+)
15 (–) Supply
24 VDC
Removable terminals
green
Collective Error Messaging
Power Rail Connection
Proof interval: approx. 1 year phone: 330 486-0002 • email: sales@us.pepperl-fuchs.com phone: +49 621 776-0 • email: pa-info@de.pepperl-fuchs.com phone: +65 67799091 • email: sales@sg.pepperl-fuchs.com
Input Input Mech. Output Status display Output III Status display
SN-Sensor S1N-Sensor Contact I + II LED yellow Fault signal LED red
The input signals must be generated by safety-aligned proximity sensors (Fail Safe
technology) from Pepperl+Fuchs or appropriately approved mechanical contacts. The
prerequisite for correct functioning with mechanical switches, is that a series resistance of
1.5 kΩ and a parallel resistance of 10 kΩ be applied directly at the contact.
The dynamic signal processing safeguards the continual control of all the incorporated
electronic components of the sensor circuit and of the isolating switch amplifier.
Installation conditions:
• The prescribed ambient conditions must be observed.
• The installation conditions of the proximity sensor must also be followed.
• The proximity sensor and its related actuating element are to be secured against
becoming loose from their fixing.
Section 12 ❖❖❖
Additional Information ANSI/UL 698 Standard for Industrial Control Equipment for
Use in Hazardous Locations, Class I, Groups A,
B, C and D and Class II, Groups E, F and G
Bibliography
Bass, H.G., Intrinsic Safety, Quartermainte House, Ltd., Sunbury, ANSI/UL 913 Standard for Intrinsically Safe Electrical Circuits
Middlesex, U.K., 1984. and Equipment for Use in Hazardous Locations
Calder, W., Magison, E.C., Electrical Safety in Hazardous UL Standards Available From:
Locations, Instrument Society of America, North Carolina, U.S.A.,
1983. Underwriters Laboratories, Inc.
333 Pfingsten Road
Garside, R., Intrinsically Safe Instrumentation: a guide, Safety Northbrook Illinois 60062
Technology, Ltd., Feltham, Middlesex, U.K., 1997.
❖❖❖
Magison, E.C., Electrical Instruments in Hazardous Locations, 4th
Ed., Instrument Society of America, North Carolina, U.S.A., 1998. ANSI/ISA-12.00.01-2002 Electrical Apparatus for Use in
(IEC 60079-0 Mod) Class I, Zones 0, 1, & 2 Hazardous
Magison, E.C., Intrinsic Safety, Instrument Society of America, Locations: General Information
North Carolina, U.S.A., 1984.
ANSI/ISA-12.00.01-1999 Definitions and Information Pertaining
Magison, E.C., Electrical Instruments in Hazardous Locations, 3rd to Electrical Instruments in Hazardous
ed., Instrument Society of America, North Carolina, U.S.A., 1990. (Classified) Locations
Minard, A., Systems et Installations de Securite Intrinseque, ANSI/ISA-12.00.01-2002 Electrical Apparatus for Use in
Laboratoire Central des Industries Electriques, Fontenay aux (IEC 60079-11 Mod) Class I, Zones 0, 1, & 2 Hazardous
Roses, France, 1986. Locations - Intrisic Safety “i”
Redding, R.J., Intrinsic Safety, McGraw-Hill, Ltd., Berkshire, U.K., ISA-RP12.2.02-1969 Recommendations for the
1971. Preparation, Content, and
Organization of Intrinsic Safety
Control Drawings
Reference Standards
ISA-RP12.4-1996 Pressurized Enclosures
United States
ISA-12.04.01-2003 Electrical Apparatus for Exlposive
ANSI/NFPA 70 National Electrical Code, Articles 500-505, (IEC 60079-2 Mod) Gas Atmospheres - Part 2
Hazardous (Classified) Locations Pressurized Enclosures
ANSI/NFPA 496 Purged and Pressurized Enclosures for ANSI/ISA-12.06.01-2003 Recommended Practice for Wiring
Electrical Equipment in Hazardous (Classified) Methods for Hazardous (Classified)
Locations Locations Instrumentation Part 1:
ANSI/NFPA 497 Classification of Flamable Liquids, Gases, Intrinsic Safety
or Vapors and of Hazardous (Classified) ANSI/ISA-12.12.01-2000 Nonincendive Electrical Equipment
Locations for Electrical Installations in for Use in Class I and II, Division
Chemical Process Areas 2 and Class III, Divisions 1 and 2
Hazardous (Classified) Locations
NFPA Standards Available From:
ANSI/ISA-12.12.02-2003 Electrical Apparatus for Use in Class
National Fire Protection Association I, Zone 2 Hazardous (Classified)
Batterymarch Park Locations - Type of Protection “n”
Quincy, Massachusetts 02269
ISA Standards Available From:
FM 3610 Intrinsically Safe Apparatus and Associated The Instrumentation, Systems and Automation Society
Apparatus for Use in Class I, II, and III, Division 67 Alexander Drive
1 Hazardous Locations P.O. Box 12277
Research Triangle Park, North Carolina 27709
FM 3615 Explosion-proof Electrical Equipment
C22.2-213 Non Incendive Electrical Equipment for Use in EN60079-1 (EN50018) Flameproof Enclosure “d”.
Class I, Division 2 Hazardous Locations EN60079-7 (EN50019) Increased Safety Protection
Method “e”.
CSA Standards Available From:
EN50020 Intrinsic Safety Protection Method “i”.
Canadian Standards Association
178 Rexdale Boulevard EN60079-25 (EN50039) Intrinsically Safe Systems “i”.
Rexdale (Toronto), Ontario, Canada M9W IR3
CENELEC Standards Available From:
International CENELEC
IEC 60079-0 General Requirements 35, Rue de Stassartstraat
B-1050 Brussels, Belgium
IEC 60079-1 Electrical Apparatus - Type of Protection “d”
IEC 60079-2 Electrical Apparatus - Type of Protection “p” Internet Resources
IEC 60079-4 Method of Test for Ignition Temperature Instrumentation, Systems and Auomation Association (ISA):
www.isa.org
IEC 60079-5 Electrical Apparatus - Type of Protection “q”
American National Standards Institute (ANSI): www.ansi.org
IEC 60079-6 Electrical Apparatus - Type of Protection “o”
International Electrotechnical Commission (IEC): www.iec.ch
IEC 60079-7 Electrical Apparatus - Type of Protection “e”
Environmental Protection Agency (EPA): www.epa.gov
IEC 60079-10 Classification of Hazardous Areas
Occupational Safety and Health Association (OSHA): www.osha.gov
IEC 60079-11 Electrical Apparatus - Type of Protection “i”
TÜV: www.tuvps.com
IEC 60079-15 Electrical Apparatus - Type of Protection “n”
Factory Mutual (FM): www.factorymutual.com
IEC 60079-18 Electrical Apparatus - Type of Protection “m”
Underwriters Laboratory (UL): www.ul.com
IEC 60079-25 Intrinsically Safe Systems
Canadian Standards Association (CSA): www.csa.ca
IEC Standards Available From:
National Electrical Manufacturers Association (NEMA):
IEC Central Office www.nema.org
3, Rue de Varembé
CH-1211 Geneva 20 European Commitee for Electromechanical Standardization
Switzerland (CENELEC): www.cenelec.org
National Fire Ptrotection Association (NFPA): www.nfpa.org
Organizations such as NEMA, CSA, UL, IEC and TÜV have of intrinsic safety, IEC 60529 has no equivalents to the NEMA
developed rating systems for the identification of an enclosure’s hazardous location enclosure Types 7, 8, 9 and 10. The North
ability to withstand and repel the outside environment. NEMA, American system also includes a 4X rating that indicates
CSA and UL are the systems most often used in North America. resistance to corrosion.
The European rating system, developed by IEC and TÜV The following tables show the enclosure types for non hazardous
Rhineland, is very similar to the North American system for non and hazardous locations according to NEMA standards, and
hazardous location enclosures. But because, historically, the an approximate cross-reference for the North American and
European system has been more deeply rooted in the concept European rating systems.
1 Intended for use primarily to provide a degree of protection against limited amounts of falling dirt.
2 Similar to Type 1 but with addition of drip shields used where condensation may be severe.
Intended for outdoor use primarily to provide a degree of protection against rain, sleet, windblown dust, and damage from external ice for-
3 mation.
3R Intended for outdoor use primarily to provide a degree of protection against rain, sleet, and damage from external ice formation.
Intended for outdoor use primarily to provide a degree of protection against rain, sleet, windblown dust, and to provide for operation of
3S external mechanisms when ice laden.
Intended for indoor or outdoor use primarily to provide a degree of protection against windblown dust and rain, splashing water, hose-
4 directed water, and damage from external ice formation.
Intended for indoor or outdoor use primarily to provide a degree of protection against corrosion, windblown dust and rain, splashing water,
4X hose-directed water, and damage from external ice formation.
Intended for indoor or outdoor use primarily to provide a degree of protection against hose-directed water, the entry of water during occa-
6 sional temporary submersion at a limited depth, and damage from external ice formation.
Intended for indoor or outdoor use primarily to provide a degree of protection against hose-directed water, the entry of water during pro-
6P longed submersion at a limited depth, and damage from external ice formation.
12 Intended for indoor use primarily to provide a degree of protection against circulating dust, falling dirt, and dripping non-corrosive liquids.
12K Type 12 with knockouts.
Enclosures are intended for indoor use primarily to provide a degree of protection against dust, spraying of water, oil, and non corrosive
13 coolant.
7 Intended for indoor use in locations classified as Class I, Groups A, B, C, or D, as defined in the National Electrical Code.
8 Intended for indoor or outdoor use in locations classified as Class I, Groups A, B, C, or D, as defined in the National Electrical Code.
9 Intended for indoor use in locations classified as Class II, Groups E, F, or G, as defined in the National Electrical Code.
10 Constructed to meet the applicable requirements of the Mine Safey and Health Administration.
1 ✓
2 ✓
3 ✓
3R ✓
3S ✓
4 ✓
4X ✓
6/6P ✓
12/12K ✓
13 ✓
1
IEC 60529 has no equivalents to NEMA enclosure Types 7, 8, 9 or 10.
IEC Definitions
The IEC 60529 standard defines Ingress Protection as a two digit code. The first digit describes the
degree of protection against access to hazardous parts and ingress of solid objects. The second
digit designates the Ingress Protection against water. Please refer to the appropriate sections of IEC
60529 for complete information regarding applications, features, and design tests.
Resistive Circuits
Minimum igniting currents applicable
to electrical apparatus with cadmium,
2A zinc, magnesium or aluminum.
The maximum permissible working
current will be two thirds of the
values shown.
500 mA
METHANE
Group I **
200 mA PROPANE
Group IIA (D)*
100 mA
50 mA
ETHYLENE
Group IIB (C)*
HYDROGEN
Group IIC (A&B)*
20 mA
10 mA
10 20 50 100 200
V
3,000 µF
Capacitive Circuits
Minimum igniting voltages applicable to
Class I, Groups A and B (Group II, C)
electrical apparatus.
1,000 µF The curve marked Sn is applicable only
where cadmium, zinc or magnesium can be
excluded.
The maximum permissible working voltage
300 µF will be two thirds of the values shown.
100 µF
C + 40 Ω (Cd)
C + 15 Ω (Cd)
30 µF
C + 5.6 Ω (Cd)
C
10 µF
3 µF
C + 0 Ω (Sn)
1.0 µF
C + 0 Ω (Cd)
0.3 µF
0.1 µF
0.03 µF
0.01 µF
1 3 10 30 100 300 1,000 3,000
3,000 µF
Capacitive Circuits
Ignition voltages in methane. The
curves correspond to values of current
limiting resistance as indicated.
1,000 µF The curve marked Sn is applicable only
where aluminum, cadmium, magnesium
and zinc can be excluded.
300 µF
100 µF
C + 40 Ω (Cd)
C + 15 Ω (Cd)
30 µF
C + 5.6 Ω (Cd)
C
10 µF
3 µF
C + 0 Ω (Sn)
1.0 µF
C + 0 Ω (Cd)
0.3 µF
0.1 µF
0.03 µF
0.01 µF
1 3 10 30 100 300 1,000 3,000
Inductive Circuits
500 mH
Minimum igniting currents applicable to
electrical apparatus with cadmium, zinc,
magnesium or aluminum where U = 24 V.
The maximum permissible working current
will be two thirds of the values shown.
200 mH
100 mH
METHANE
Group I **
50 mH
PROPANE
20 mH Group IIA (D)*
L
10 mH
5 mH
ETHYLENE
Group IIB (C)*
2 mH
1 mH
HYDROGEN
Group IIC (A&B)*
Certification.Curves.Showing.Relationship
Between.Inductance.and.Minimum.Igniting.Current
10
Inductance.Circuits
Igniting currents for various
10.µH voltages in Group B.
Applicable to all circuits
.µH containing aluminum, cadmium,
magnesium or zinc.
100.µH
Minimum.value.of.Isc.for.ignition.(A)
1.0
1.mH
0.1 10.mH
100.mH
0.01
10 100 500
Open.circuit.voltage.Voc.(V)
Australia Germany
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PO Box 467, Goodna Q 4300 38116 Braunschweig
+61 7 3810 6333 +49 (0 )531 592 0
Japan
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Laboratorio Official Jose Maria de Madariaga (LOM)
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