Intrinsically explosion-proof and safety barrier introduction

Summary of Topics Page

1. Explosion basic knowledge 1
2. Explosion groups 1
3. Zone classification 2
4. Explosion-proof electrical apparatus design standards 3
5. Explosion-proof mark of different countries 3
6. Explosion-proof type of electrical apparatus 3
7. The basic principles of the intrinsically explosion-proof technology 4
8. The feature of the intrinsically explosion-proof technology 4
9. Intrinsically safety apparatus and associated apparatus 5
10. Intrinsic safety electrical apparatus type 5
11. Marking of apparatus 6
12. The basic components of intrinsically safe explosion-proof system 7
13. Safety barrier 9
14. Guidelines for use of devices with intrinsically safe circuits 11

1. Explosion basic knowledge

Explosion is that the material produces a high-speed exothermic reaction. In order to have an explosion,
the following three components must be present simultaneously:
NO. component interpretation
1 Fuels (flammable Flammable concentrations of gases and vapours or solids which have the
substances) potential for igniting an explosion
2 Oxidizers air (21 % Oxygen), pure Oxygen, oxygen releasing compounds (i.e. potassium
manganate)
3 Possible sources hot surfaces, flammable or explosive gases, mechanically generated sparks,
of ignition electrical installations, transient currents, static electricity, lightning,
ultrasonic energy...
4 Explosive limits A mixture is only explosive when its concentration falls within certain
material specific limits. These limits are called the upper and lower explosive
limits and are listed in according tables.

2. Explosion groups
GB3836-2000 ordains that combustible materials are divided into the following classes in accordance with
the degree of the inflammable hierarchy.

Classification Representative The min. energy Inflammable

Factory type
of the gases gases detonating the spark hierarchy
Underground the miner Ⅰ Methane 0.280mJ Difficultly
he factory outside miner ⅡA Propane 0.180mJ ↓

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 ⅡB Ethylene 0.060mJ easily
Hydrogen,
ⅡC 0.019mJ
acetylene

The United States of America and Canada (NEC500) divide the explosive objects spreading in the air into
three classes firstly. The “CLASS Ⅰ”are gas and vapour. The “CLASS Ⅱ” is dust. The “CLASS Ⅲ” is
fiber. Then divide the gas and vapour into Group:
Representative gases or China/IEC/European countries’ corresponding
Class group
dusts class (GB3836.1/IEC60079-0/EN50014)
A Acetylene ⅡC (Hydrogen, Acetylene)
B Hydrogen ⅡC (Hydrogen, Acetylene)
CLASS Ⅰ
C Ethylene ⅡB (Ethylene)
D Methane ⅡA (Propane)
E Metal dusts Ⅰ(Methane)
CLASS Ⅱ F Coal dusts
G Grain dusts To be determined(Ⅲ)
CLASS Ⅲ Ⅲ No grouping

3. Zone classification
According to EN 60079-10 and EN 1127-1 explosion hazardous areas are divided into zones such as
flammables gases, vapours, mists and combustible dust. The classification is based on the likelihood that a
dangerous explosive atmosphere occurs. The ATEX directive has re-defined the zone division as follows:
Likelihood of an
explosive Likelihood of an
Likelihood of an
atmosphere : explosive
explosive
China occasionally atmosphere: unlikely
atmosphere:
continuously, for or infrequently - for a
China Description occasionally
long periods or short period only
IEC
frequently
European
constant or long occasionally seldom or short term
Union European
term corresponds corresponds to corresponds to < 10
Union
to > 1000 h/year 10...1000 h/year h/year
gases and
Zone zone 0 zone 1 zone 2
vapours
classification
dusts zone 20 zone 21 zone 22

North
America Description Under normal operating conditions, it The flammable gas or
continuously, intermittently or vapor will release and
periodically exist the flammable gas become dangerous
or vapor and the concentrations reach only when the
a dangerous level. container rupture, the
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equipment anomalies
 abnormal operate
occasionally.
Zone classification (gases Div.1 Div.2
and dusts)

4. Explosion-proof electrical apparatus design standards

country Standards Code Standards Name
Electrical apparatus for explosive gas
GB3836.1-2000
atmospheres--Part 1:General requirements
Country Standards
Electrical apparatus for explosive gas
GB3836.4-2000
atmospheres--Part 4:Intrinsic safety
IEC60079-0:1998
IEC
IEC60079-11:1999
European Committee for
EN 50020 Intrinsic safety
Standardization(CENELEC)
North American (America,
NEC500
Canada)
Country Standards GB3836-2000 is equivalent to adopting IEC 60079.

5. Explosion-proof mark of different countries

mark signification
Ex Explosion-proof mark of China and IEC
EEx European economic community
AD Italy
MS､AE France
FLP Great Britain
UL､FM America
E Germany \IEC

China National Quality Supervision and Test Centre for Explosion Protected Electrical Products (CQST):
CQST is one of the China famous professional testing and certification authorities and engages in safety
test, examination and evaluation of Ex electrical products. CQST has made deep research and obtained
extensive experience in the field of explosion protection electric safety technique and has a high reputation
in the word.
CQST has signed the cooperation agreements of mutual acceptance of test results separately with more
than ten international wellknown Ex scientific research and test bodies, such as UL (U.S.A.), FM (U.S.A.),
PTB (Germany), NEMKO (Norway), testsafe (Australia), CCVE (Russia) and LCIE (France).These
cooperation have promoted the international exchange of Ex technique and offered convenient services for
sino-foreign Ex product entering into opposing side market.

6. Explosion-proof type of electrical apparatus

GB3836-2000 (Electrical apparatus for explosive gas atmospheres) defines as follows:

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 code type standards explosion-proof measure application zone
d flameproof GB3836.2 Isolate the ignition source Zone1,Zone2
existing
e increased safety GB3836.3 Try to prevent producing the Zone1,Zone2
ignition source
ia intrinsic safe GB3836.4 Limit the energy of the ignition Zone0-2
source
ib intrinsic safe GB3836.4 Limit the energy of the ignition Zone1,Zone2
source
p Pressurized GB3836.5 Isolate the hazardous substance Zone1,Zone2
and the ignition source
o jelly filled GB3836.6 Isolate the hazardous substance Zone1,Zone2
and the ignition source
q sand filled GB3836.7 Isolate the hazardous substance Zone1,Zone2
and the ignition source
n non-sparking GB3836.8 Try to prevent producing the Zone2
ignition source
m pour enveloping GB3836.9 Try to prevent producing the Zone1,Zone2
ignition source
h hermetically sealed GB3836.10 Try to prevent producing the Zone1,Zone2
ignition source
For automatic control and instrumentation, intrinsic safe, flameproof and increased safety types are used
commonly.

7. The basic principles of the intrinsically explosion-proof technology

In electrical apparatus, electric spark and thermal effect is the main ignition sources that set danger
explosive gas off. The intrinsic safety methods are considered protection devices and their function is to
avoid possible errors and faults by preventing the transfer of unsafe levels of energy to the hazardous area.
Possible faults are: 1) Excessive voltage in the hazardous area. 2) High current levels in the hazardous area
(short-circuit).
The intrinsic safety method of explosion protection always relates to intrinsically safe circuitry that
comprises an intrinsically safe apparatus, an appropriate electrical power source and the connecting cables.
In intrinsically safe circuits, an explosive environment cannot be ignited by sparking or a thermal effect
when operating normally under prescribed fault conditions. In an intrinsically safe circuit for categroy ia, 2
calculable faults (see definition EN 50020) must not cause an ignition and in category ib only 1 such fault
is permissible.
Limiting the power supply, total inductance and total capacitance within the intrinsically safe circuitry is
the basic principle of the intrinsically safe explosion protection method. The project manager or user has to
compare the permissible internal limit values for intrinsically safe electrical apparatus with the permissible
connection values of the associated electrical apparatus.

8. The feature of the intrinsically explosion-proof technology

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Intrinsically safe explosion-proof technology is actually a low-power design technology. It is a very good
apparatus for the design of industrial automation instrument. Compared with other explosion-proof type,
using the explosion-proof electrical technology has following characteristics:
1. Intrinsically electrical apparatus have simple structure, small size, light weight.
2. Installation and maintenance can be with power input.
3. High security and reliability. Do not reduce the security and reliability of the electrical apparatus for
outside structural damage.
4. Applicable range is wide range. It is the only explosion-proof technology that can be applied in the
zone 0.

9. Intrinsically safety apparatus and associated apparatus

a. Intrinsically safety apparatus
In the conditions of the national standards, any spark and thermal effects produced by this electric
apparatus can not ignite the explosive gas environment It can be used in hazardous area.
It can be divided into general electrical apparatus and simple electrical apparatus.
General electrical apparatus: Has the energy storage element, need explosion-protection
authentication. Such as intrinsically transmitter, approach switch, and so on.
Simple electrical apparatus:If Voltage is lower than 1.2V, current is lower than 0.1A,energy is lower
than 20uJ or power is lower than 25mW, it is considered as simple electrical apparatus . Do not need
explosion-protection authentication, can directly access to the intrinsically explosion-protection
system. Typical feature as followers: Internal equivalent inductance Li = 0, Internal equivalent
capacitance Ci = 0. Common simple apparatuses are: thermocouples, thermal resistors, resistor, light
emitting diode, contact switch, and so on.

b. Associated apparatus (safety barrier)

It is an apparatus installed in a safety area, connecting the intrinsically electric apparatus and
non-intrinsically electric apparatus. Safety barrier limit the energy get in to the hazardous area in the
safety rang and ensure that the field equipment, personnel and production are safety.

10. Intrinsic safety electrical apparatus type

a. Apparatus groups
According to the principle of GB3836-2000, intrinsic safety electrical apparatus has 2 types as
follows:
Group interpretation
Device Group I For mining underground with a potential hazard due to firedamp and/or
combustible dusts.
Device Group II For all other locations in which a potentially explosive atmosphere exists. There
are three class of A, B and C｡

b. Apparatus Category
Intrinsic safety electrical apparatus and associated apparatus can be divided into ia class and ib class
according to the places used or connected and the safety standards.
Code interpretation

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 ia Very high level of safety: devices featuring two independent means of protection;
even in the event of rare device disturbances, the device remains functional and
maintains the requisite level of protection. It can be used in the hazardous areas of
zone0, zone1 and zone2.
ib High level of safety: devices featuring one means of protection. Even in the event of
frequently occurring device disturbances or equipment faults which normally have to
be taken into account the device provides the requisite level of safety. It can be used
in the hazardous areas of zone1 and zone2.

c. Install temperature class

The temperature class indicates the maximum surface temperature of an apparatus and must be lower
than the minimum ignition temperature of the flammable material to prevent an ignition. The ignition
temperature (defined as the temperature at which a mixture self-ignites during testing) directly relates
to the temperature class. see table below.
ignition
temperature Maximum surface Electrical
temperatures of Common explosive gas
class temperature safety
flammable materials
Hydrogen, acrylonitrile,
T1 ≤ 450℃ ≤ 450℃
etc. (46 kinds)
Ethane, ethylene, etc.
T2 ≤ 300℃ ≤ 300℃
(47 kinds)
Petrol, crotonaldehyde ,
T3 ≤ 200℃ ≤ 200℃ Low
etc. (36 kinds)
↓
Acetaldehyde, High
T4 ≤ 135℃ ≤ 135℃ tetrafluoroethylene, etc.
(6 kinds)
T5 ≤ 100℃ ≤ 100℃ carbon disulfide
ethyl nitrate and ethyl
T6 ≤ 85℃ ≤ 85℃
nitrite
Intrinsically safe equipment for direct installation in hazardous areas requires temperature
classification. For associated apparatus temperature classification is not needed.

11. Marking of apparatus

Equipment for explosion protected areas must be clearly marked. There are two different types of marking.
According to CENELEC marking of an apparatus conforming to EN 50014/20 must provide the following
information:
– Manufacturer’s name or trademark
– Part number
– EEx-symbol
– Ignition category (e. g. ia”)
– Designated group together with the respective subdivision (e. g. IIC)
– Temperature class or maximum surface temperature (for group II devices only)

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 – Serial number (may be omitted if space is restricted)
– Test authority, date and file number
– ”X” after the test certificate number indicates that special conditions must be met (see certificate for
special conditions)
An intrinsically safe apparatus could have the following marking:

Ex ia ⅡC T6
temperature class
explosion group

type of protection

conform to IEC or chian standard

An associated apparatus could have the following marking:

associated apparatus

[Ex ia]ⅡC

explosion group

type of protection

conform to IEC or chian standard

12. The basic components of intrinsically safe explosion-proof system

Hazardous Area Safe Area

Associated Centralized
Intrinsically Control
cable apparatus
Safety System/
(safety
apparatus PLC/
barrier) Operation
Terminal

Intrinsically performance certification parameter of intrinsically electrical apparatus:

① Maximal Input Voltage (Ui):The maximal voltage put on the intrinsically safety apparatus, and can not
lead to the intrinsically performance failure (AC peak or DC).
② Maximal Input Current (Ii):The maximal current put on the intrinsically safety apparatus, and can not
lead to the intrinsically performance failure (AC peak or DC).
③ Maximum Input Power (Pi):The intrinsically current maximum input power that may consume in the
intrinsically safety apparatus inside when the intrinsically safety apparatus connects with the external
power and do not lead to the intrinsically performances failure.

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④ Maximum internal Equivalent Capacitance (Ci): Total equivalent capacitance inductance appearing by
the intrinsically safety apparatus.
⑤ Maximum internal Equivalent Inductance (Li): Total equivalent internal inductance appearing by the
intrinsically safety apparatus.

Intrinsically performance certification parameter of associated apparatus (safety barrier):

① Maximal Voltage (AC RMS or DC Um):The maximal voltage put on the associated apparatus (safety
barrier), and can not lead to the intrinsically performance failure
② Maximum Output Voltage (Uo):The maximum Output Voltage that may appear in the intrinsically
current when open circuit and the intrinsically safety apparatus voltage (including the Um and Ui ) is
maximal (AC peak or DC).
③ Maximum Output Current (Io):The intrinsically current maximum current that come from the
intrinsically safety apparatus (AC peak or DC).
④ Maximum Output Power (Po):The intrinsically current maximum power that can from the intrinsically
safety apparatus.
⑤ Maximum external Capacitance (Co):The intrinsically current maximum capacitance that can connects
to the intrinsically safety apparatus and do not lead to the intrinsically performances failure.
⑥ Maximum external Inductance (Lo):The intrinsically current maximum inductance that can connects to
the intrinsically safety apparatus and do not lead to the intrinsically performances failure.

Patch cable:Intrinsically cable is a low capacitance and low inductance cable. Compared with other cable
has excellent shielding and anti-interference performance. It suits for explosion hazardous area and having
high explosion-proof security requirement. Its intrinsically performance as follows:
Maximum distribution capacitance that the cable allow: Cc = Ck * L
Maximum distribution inductance that the cable allow: Lc = Lk * L
Ck ——Distributed capacitance per unit length of the cable
Lk ——Distributed inductance per unit length of the cable
L ——The actual length of the cable

The various configuration of the intrinsically explosion-protection system must meet the following
conditions:
1. The explosion-protection mark class of the intrinsically safety apparatus can not higher than the
associated apparatus (safety barrier).
2. Authentication parameters have to satisfy the following inequality between the associated apparatus,
intrinsically safety apparatus and the cable.
Associated Demonstration of intrinsic Intrinsically safe
apparatus safety apparatus apparatus + cable
Uo ≤ Ui
Io ≤ Ii
Po ≤ Pi
Co ≥ Ci + Cc
Lo ≥ Li + Lc

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13. Safety barrier
Some special industrial fields not only need the two-wire transmission for signal isolation and providing
power input, but also need the explosion-protection performance about safety spark-proof and reliably
avoiding the high voltage and signal contacting. Using the current and voltage double limiting loop,
limiting the energy getting into the hazardous area lower than the ration, these can improve the
explosion-protection performance of the intrinsically system, at the same time increase the
anti-interference ability greatly enhanced the reliability greatly of the system. These field products having
specific function are safety barrier.
Safety barrier is used in the design of an intrinsically explosion-proof system. It is installed in a safety area.
Safety barrier is an apparatus with intrinsically current and non-intrinsically. These current limits the
energy get in to the hazardous area by limiting the current and limiting the voltage, then avoid the
hazardous energy enter into the hazardous area. Safety barrier is named associated apparatus, it is an
important component of the intrinsically system.

Because the safety barrier is designed as an interface between the field apparatus and the control room
apparatus, no matter the control room apparatus is in normal or fault, safety barrier both can ensure the
energy send to the field through it is intrinsically safe.

According to signal direction, Safety barrier have two types as follow:

Ⅰ. Detection type safety barrier:
Detection type safety barriers usually are used with the transmitter at hazardous area. The functions as
follow: a. Convert the signal from the hazardous area to standard current or voltage signal, isolate,
and transmit it to safety area. B. Limit the risk energy getting into s hazardous area from intrinsic
safety terminal. C. Give isolation power distribution to the field transmitter.
Ⅱ. Operation type safety barrier:
Operation type safety barrier usually are used with the current to pneumatic converter or electric
appliance valve positioner at hazardous area. The functions as follow: a. Isolate and transmit the
current signal from the safety area to the hazardous area, and driver the field actuating element
(current to pneumatic converter ), etc. b. Limit the risk energy getting into s hazardous area from
intrinsic safety terminal. C. Give isolation power distribution to the safety area.

Safety barrier can be devided into zener safety barrier and isolation safety barrier according to
construction.
Ⅰ. Zener safety barrier
The current uses the rapid fuse, current-limiting resistance or voltage-limiting diode to limit the input
energy, thus ensue the energy output to the hazardous area. The principle as follows:

Hazardous Safe
Area Area

Zener safety barrier have simple principle. Its current can achieve easily and the price is cheap. But the

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 application reliability is affected greatly for its principle defect and this limits its application range. The
reason as follows:
a. Installation location must have reliable ground system, and the ground must be less than 1Ω,
otherwise it would lose the explosion-protection performance and reduce signal anti-interference
capacity directly, affect the stability of the system.
b. The instrument from hazardous area must is isolation type, or the signal connected to the ground by
the ground terminal of the zener safety barrier can not transmit correctly, and because of signal
grounding, it will reduce signal anti-interference capacity directly, affect the stability of the system.
c. Zener safety barrier has greater impact on the power supply, at the same time it can be damaged
easily for the instability of the power supply.
d. Using zener safety barrier, signal negative pole all need to the intrinsically ground, it will reduce
signal anti-interference capacity directly, affect the stability of the system., the impact on the DCS
system is sharp prominent.

Ⅱ. Isolation safety barrier

Isolation safety barrier is composed of limiting energy unit, isolation unit, signal process unit, power
supply unit, etc. The principle as follows:

Hazardous Safe
Area Area

limiting Isolation signal

energy unit process
unit unit
Isolation safety barrier not only has limiting energy function, but also has isolation function, at the same
time in accordance with intrinsically limiting energy requirements. Compared to zener safety barrier,
although the price is slightly higher, but its others outstanding advantage give more benefits to user.
a. Transformer isolated barriers do not require grounding, because the transformer in the barrier
galvanically isolates the hazardous area from the safe area.
b. Transformer isolated barriers have an internal voltage regulator. The function necessary to the
application is thereby assured.A regulated power supply is only necessary for Zener barriers. If the
power supply for Zener barriers is too low, the field device can no longer operate. The same applies to:
If the power supply becomes too high, the Zener diodes divert the current and the fuse blows when
the current exceeds its maximum rating.
c. Any process monitoring signal circuit (mA- or mV-signal) that is connected to a transformer isolated
barrier is not grounded. In contrast to this, Zener barriers require a suitable ground. From an
instrumentation point of view this is best achieved through a quasi ungrounded system.
d. Transformer isolated barriers from MORNSUN can be repaired; Zener barriers cannot, because they
are filled with an epoxy resin.
e. Transformer isolated barriers have an internal current limit. The fuse is not activated if there is a short
circuit at the exterminal.
f. Instead of using diagrams and Ohm's Law to determine the proper barrier, each transformer isolated
barrier is designed for special applications (i. e. 4 mA~20 mA amplifier, thermocouple amplifier,
solenoid drivers, etc.)

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 According to the function, the types of safety barrier commonly used are as follows: switch safety
barrier, analog safety barrier, digital safety barrier, resistance thermometry safety barrier, thermocouple
safety barrier, frequency safety barrier, and so on.

14. Guidelines for use of devices with intrinsically safe circuits

The principle of selecting the intrinsic safety electrical apparatus
Simple electrical apparatus:
According to the principle of GB3836.4-2000 about explosion-protection standards, if voltage is lower than
1.2V, current is lower than 0.1A, energy is lower than 20uJ or power is lower than 25mW, it is considered
as simple electrical apparatus. Typical feature as followers: Internal equivalent inductance Li = 0, Internal
equivalent capacitance Ci = 0. Common simple apparatuses are: thermocouples, thermal resistors, pH
electrode, strain gauge, switch, and so on.
General electrical apparatus:
a. The design whether or not in accordance with the GB3836.1-2000 and GB3836.4-2000 requirements and
if the electrical apparatus had been approved by the explosion-proof inspection agency which was
authorized by the national.
b. If the explosion-proof mark class is applicable to the safety requirements of the hazardous area.
c. Clear the authentication parameters of Ui, Ii, Pi, Ci and Li.
d. If intrinsically safety current ground or if it is isolated effectively between the grounding intrinsically
current and the safety barrier interface current.
e. What is the method of the signal transmission?
f. Clear the minimum operating voltage and loop normal operating current of the intrinsically electrical
apparatus.

The principle of selecting the safety barrier

a. Safety barrier’s explosion-proof mark class is not lower than the class of the intrinsically field apparatus.
b. Make sure the end and circuit resistances can meet the minimum operating voltage of the intrinsically
field apparatus.
c. Safety barrier’s safety parameters of the intrinsically port can conform to Uo≤Ui, Io≤Ii, Co≥Ci+Cc,
Lo≥Li+Lc.
d. The safety and the signal transmission mode between the safety barrier and the intrinsically field
instrument must be best match.
e. Do protection well. Avoid leakage current of the safety barrier affects the normal operation of the
field intrinsically safety apparatus.
f. Safety barrier have two types: one is zener safety barrier, the other is isolation safety barrier.

The principle of selecting the cables

The governing regulations cover installation of intrinsically safe circuits, mounting to external connections,
cable characteristics and cable installation. Cables and terminals with intrinsically safe circuits must be
marked and separated from nonintrinsically safe circuits or feature appropriate isolation (> 1.500 VAC).
Following an excerpt from the requirements according to EN 60079-14:
a. Protection against external electrical or magnetic fields (e.g. power current cables).
b. Prevent conductor splicing of fine wires through wire sleeves.
c. Min. cross section of 0.1 mm (also single wires of a conductor).
d. Protection against damaging (mechanical, chemical, thermic...)
e. Armouring, metal cladding, shielding of cables and lines

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f. Common use of single-core nonsheathed cables of intrinsically and nonsafe circuits in one line is not
permitted.
g. Separate error assessment when using multi-conductor cables and lines.
h. When marking cables by colour, light-blue must be used.

Installation of cables
Electrical cables are the connection between field and interface devices and are important functional
components of an automation system. Therefore it is advisable to observe some frame conditions when
installing cables. Cables must be protected against negative environmental influences.
Chemical resistance, temperature rating, resistance against ultraviolet radiation and applicable operation
standards are just some of the parameters which should be taken into account.
By choosing an appropriate installation method it is possible to prevent damages, e.g. through vehicles.
When connected to field devices, the cable should be routed in a conduit. If connected to vibrating
machines or moving parts, some extra cable should be added as a reserve. The minimum bending radius
must also be observed. Cable manufacturers provide information on cable installation and valuable
installation hints. Data integrity and reliability depend strongly on the cable types and installation methods.
Sensor cables should always be installed separately from the power cables. Electromagnetic interferences
must also be avoided. Cable connections to motors which are controlled via frequency converters should be
protected according to the manufacturer’s safety specifications. If long cables are needed, it is
recommended to use shielded and earthed cables. The line resistance of sensors may not exceed 50 Ω (EN
60947-5-6); the maximum cable length is determined by the cable' cross-section:
R ×S
L=
δ
— R = line resistance [Ω]
— S = cable cross-section [mm2]
— δ = resistivity [Ω×mm2/m]
— L = cable length [m]

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