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CONTENTS 02/01
1 Introduction............................................................................................... 3
1.1 Document Contents .....................................................................................4
1.2 Relevant Standards and Codes of Practice.....................................................4
1.3 Hazardous areas Areas and Their Consideration ............................................4
1.4 Terminology ................................................................................................5
2 The ATEX Directive..................................................................................... 7
2.1 Equipment Categories ..................................................................................7
2.2 Apparatus Standards....................................................................................8
2.3 Summary of Requirements for Category 3 Apparatus in Zone 2 ......................9
3 DeltaV I/O Mounting Options ................................................................. 10
3.1 DeltaV I/O card types ................................................................................ 10
4 Enclosures and Junction boxes ................................................................ 12
4.1 General Requirements................................................................................ 12
4.2 Unused openings ...................................................................................... 13
4.3 Cable Entry Devices (glands) ...................................................................... 13
5 Cables and wiring..................................................................................... 14
5.1 General ..................................................................................................... 14
5.2 Avoidance of Damage ................................................................................ 14
5.3 Internal Cabinet Wiring .............................................................................. 14
5.4 Passage and Collection of Flammables ........................................................ 14
6 Grounding and Bonding of Zone 2 Systems ............................................ 15
6.1 General Precautions ................................................................................... 15
6.2 IS DeltaV Field Wiring ................................................................................ 15
6.3 Power Supplies .......................................................................................... 15
6.4 Field Enclosures......................................................................................... 16
7 Labeling ................................................................................................... 17
7.1 General ..................................................................................................... 17
8 Maintenance of DeltaV IS I/O Cards in Zone 2........................................ 18
8.1 Permissible live-working in Zone 2 .............................................................. 18
8.2 Prohibited live-working in Zone 2................................................................ 18
9 Appendix A ............................................................................................... 20
9.1 IS I/O components for installation in Zone 2 ............................................... 20
9.2 DeltaV IS I/O card safety parameters ......................................................... 21
1 Introduction
This document is intended as a guide for the selection, installation, and maintenance of the
intrinsically safe I/O cards that form part of a DeltaV control system and applies to
equipment that has been designed to:
mount in a Zone 21 hazardous area
connect to intrinsically safe apparatus located in a Zone 1 or a Zone 0 hazardous area
It should be read in combination with the Zone 2 requirements of each I/O card, as
documented in the appropriate ATEX Category 3 Certificate.
Note that the requirements for intrinsically safe circuits are outside the scope of this
Code of Practice. EC-Type examination certificates have been issued by an ATEX
Notified Body (Baseefa) which approves the products as Associated Apparatus
with field connections in Zone 0 or Zone 1. A system certificate has also been
issued by Baseefa which, in combination with installation drawings approved by
them, defines the requirements for Zone 0 and Zone 1 field wiring. It is essential
that all requirements of these documents and of the CENELEC intrinsically safe
system installation standard EN 60079-25 are met for Zone 0 and Zone 1 field
wiring.
There are two ATEX directives, one that applies to equipment manufacturers
(DeltaV) and another for its end users (DeltaV customers). Directive 94/9/EC
(ATEX 100a), sometimes called the "Manufacturers' Directive" is intended to
facilitate the free movement of goods throughout the EU by harmonizing the
technical and legal standards to which equipment for use in potentially explosive
atmospheres is manufactured.
The other directive, Directive 99/92/EC or ATEX 137, is also known as the
Workplace or User Directive. ATEX 137 details the minimum workplace
requirements for improving the health and safety protection of workers potentially
at risk from explosive atmospheres. EU customers and installations that employ
persons working in a potentially explosive atmosphere are subject to ATEX 137
Directive. This is an end-user issue and not covered in this document.
Both directives went into effect on 1 July 2003. This document covers only ATEX
Directive 94/9/EC (ATEX 100a) as it applies to DeltaV IS products.
Directive 94/9/EC of the European Parliament and the Council, dated March 23, 1994,
otherwise known as the ATEX 100a directive was created to cover the design of all
apparatus to be used in explosive atmospheres. It specifies essential safety requirements
with which apparatus must comply. Among its details it declares that apparatus can be
certified by its own manufacturer, for use within certain categories of explosive
atmospheres, without the need for intervention by external certification agencies, such as
BASEEFA, CENELEC, Factory Mutual, and so on.
DeltaV IS I/O cards and associated system components for use in Zone 2 are manufacturer-
certified by GE Intelligent Platforms as Category 3 apparatus under the ATEX directive and
this makes them suitable for use in Zone 2 hazardous areas.
In addition to providing guidelines for selecting, installing, and maintaining DeltaV IS I/O
cards, this document is intended to help the reader to understand the ATEX directive as it
relates to the DeltaV IS I/O equipment, and to become more familiar with the terminology
associated with the ATEX directive.
1
See section 1.3.3 for a definition of this terminology.
1.4 Terminology
In addition to the above classification terminology, there are a few other terms, dealing with
electrical apparatus, that occur frequently in this document.
1.4.1 Energy-Limited Circuit
An energy-limited circuit is one in which any arc, spark, or thermal effect produced during
normal operation is prevented by energy limitation from igniting the surrounding flammable
atmosphere.
1.4.2 Non-Sparking Circuit
A non-sparking circuit is one in which any arc, spark, or thermal effect capable of igniting
the surrounding flammable atmosphere is prevented from occurring by mechanical design.
Non-sparking circuits are typically not energy-limited and can contain energy levels capable
of igniting the flammable atmosphere if interrupted without further means of protection.
1.4.3 Normal Operation
Apparatus is said to be in normal operation when it conforms electrically and mechanically
with its manufacturer's published specification and performs without any fault.
Note: Opening, shorting, and grounding of the field wiring is considered to be part of normal
operation for energy-limited circuits but not for non-sparking circuits.
are not covered in this document. Please refer to the introduction to this document for other
sources of information
2
The prefix Ex is typically related to IEC certification while the EEx prefix relates to the CENELEC
standard. In this document, the certification code Ex is predominantly used but EEx could be
interchanged with Ex in almost all circumstances.
These categories have been compared with conventional methods of protection and it is
generally accepted that Ex d, Ex e, Ex n gives a level of protection equivalent to category 2.
Intrinsically safe apparatus, which achieves category ia, is generally considered to be
equivalent to category 1 apparatus; and category ib is equivalent to category 2 apparatus.
Category 3 equipment is not capable of causing ignition in normal operation; however, live
maintenance, without a gas clearance certificate, is included in the definition of normal
operation and so the combination of apparatus design and installation practice must ensure
that ignition is not possible during live maintenance.
2.1.1 Self Certification
Category 3 equipment is intended for Zone 2 installation. As there is a lower risk of the
presence of a flammable atmosphere in Zone 2, there is no requirement for third party
assessment of this equipment and self certification by the manufacturer is permitted. Self
certification is controlled through the use of a technical file and forms the basis of the
assessment. In the particular case of the DeltaV IS I/O cards, all technical files are based
on the requirements of all the relevant CENELEC, IEC and North American standards which
are considered applicable to the situation. (These standards are described more fully in
section Clause 2.2.) A certificate is available for each apparatus and it contains references to
its technical file and the relevant standards.
However, because the DeltaV IS equipment has field connections which may be connected
to wiring in Zone 0 or Zone 1, it is Associated Intrinsically Safe Apparatus and so is ATEX
FMRC Approval Standard Class Number 3611: "Electrical Equipment for Use in Class I
Division 2, Class II Division 2 and Class III Division 1 and 2 Hazardous Locations."
EN 61010-1: "Safety requirements for electrical equipment for measurement control and
laboratory use. Part 1: General Requirements"
LocalBus
Power/Controller Isolator IS System
8-wide I/O Interface 8-wide I/O Interface
Carrier Carrier Power Supply
Carrier (general Carrier (Intrinsically
purpose field wiring) Safe field wiring)
The field wiring for IS I/O cards is certified as intrinsically safe and can originate in a Zone 1
or Zone 0 hazardous area. The field circuits are certified by BASEEFA to CENELEC
standards, and are not covered under the scope of the Category 3 manufacturer-certification
for Zone 2. The national and international standards appropriate to the country of
installation, for example EN 60079-25 Electrical apparatus for explosive gas atmospheres
Part 25 Intrinsically safe systems. in CENELEC member countries, governs the installation
and maintenance of the IS field wiring.
IS I/O cards draw their power from an isolated 12V (LocalBus) system. The LocalBus
connection between an I/O card and the card carrier is always energy-limited.
Similarly, the choice of a suitable terminal is easily (and economically) settled by using an Ex
e component certified terminal which removes concern over creepage and clearance
distances and security of connection. This type of terminal also achieves an IP 20 level of
protection that is adequate to prevent inadvertent contact with live circuits when the
enclosure is open. There is no electrical safety reason for segregating energy-limited and
non-sparking circuits but they must be clearly distinguished from one another because of
the essential difference in maintenance procedures. Ideally, terminals associated with the
two different techniques should be mounted on separate rails within the junction box or
spaced out along a rail. When space is at a premium use a separator between the two
types of terminals. Terminals should be provided so that unused cores of a multicore are
safely terminated and can be used at a later date. Unused cores should be identified as
energy-limited.
Unless specifically permitted by the documentation do not connect two conductors into one
terminal unless they are secured with a single compression type ferrule.
Note that the requirements of IS wiring are not covered in this document.
To maintain the protection that is provided by the enclosure it might be necessary to use
cable entry devices (glands) that have a seal around the entering cable. A seal, such as a
washer or sealant compound, might also be required between the gland and the enclosure.
The correct choice of gland and accessories ensures the continuity of the electrical path of
the armour when armoured cable is used as part of the bonding and electrical protection
system. If you are using thread sealant, be sure it does not affect the current carrying
capacity of the joint and be especially careful when using plastic enclosures.
Note: The requirements stated in this section are derived from EN 60079-14, Clause 9.
5.1 General
Clause 9 (of EN 60079-14) specifies the requirements of cable systems. Please refer to this
and other clauses of this standard for more detailed information.
Other information regarding the design, installation and maintenance of Intrinsically Safe
systems is given in EN 60079-25 Electrical apparatus for explosive gas atmospheres Part
25 Intrinsically safe systems.
Note: Take precautions to prevent damage to the sheathing or insulation materials of PVC
cables that are to be installed at temperatures below -5C.
If necessary, seal conduits, and in special cases, cables (for example where there is a
pressure differential), to prevent the passage of liquids or gases.
ISA standard ISA-S12.10:1991 suggests that a pressure differential in excess of 1.5 kPa (6
inches of water) would require a cable to be sealed.
A system is considered to be grounded at one point if the points of connection are not more
than 10 meters apart and the voltage that can be induced between them, by foreseeable
fault currents, is less than 1 V.
When a metal field enclosure is used, ensure that the enclosure can be bonded to the plant
structure. When a plastic enclosure is used, ensure the continuity of any fault return paths
such as the armour of armoured cable. Ensure that exposed metal parts are bonded to the
structure and that screened field instrument cables are connected to the enclosure bonding
system.
7 Labeling
7.1 General
Label all systems in a strategic position, for example, label the DeltaV cabinet on the final
installation. At a minimum, the labelling should enable you to easily trace the relevant
descriptive system document. One acceptable technique is to use a clear instrument loop
number to identify the loop documentation which lists the descriptive system document.
All apparatus within the system should be readily identifiable. In the case of simple
apparatus a traceable plant identification label is acceptable.
Important: Do not disconnect the incoming feed by removing the free half of the two-part
connector at the rear of the power supply module in the hazardous area while the input
power is on.
Interconnection between the I/O card power supply (Fisher Rosemount model: IS
System Power Supply) and its carrier. Do not remove the power supply from the carrier
while its input is under power. If you must remove a power supply (for example if it
has failed in a redundant application), first power down the local supply input as
described above. Do not restore the supply input until after the power supply has
been replaced on its carrier.
(Redundant power supply applications are those in which two or more power supply
modules are installed in an n+1 arrangement. Removal of one supply is permitted
while the others are under power, provided the incoming feed to the supply to be
removed is first isolated.)
9 Appendix A
ATEX documentation for ancillary components used with the IS DeltaV System:
The I/O cards, power supplies and LocalBus Isolator used in the IS DeltaV system, intended
for mounting in Zone 2, are manufacturer-certified by GE Intelligent Platforms as Category 3
equipment in accordance with the ATEX directive. Ancillary components used to
interconnect these pieces of apparatus have not been separately certified since they have
no autonomous function. These components include card carriers, carrier extenders,
extender cables, and field terminals, as listed in the table above. Such interconnections are
not covered in the 94/9/EC directive since they are not capable of causing an explosion
through their own potential sources of ignition. This requirement is stated in Article 1
clause 3(a) of the directive. A similar argument supports the use of "simple apparatus" in
intrinsically safe systems and permits the use of uncertified cables in power systems. Hence
the use of non-certified auxiliaries in Zone 2 is not without precedent.
However such apparatus must comply with all relevant parts of the appropriate CENELEC
Standard EN60079-15 for Category 3 apparatus. The relevant parts are primarily creepage
and clearance distances, the construction of terminals and the current carrying capacity of
tracks.
All the products listed in the above table are also Associated IS apparatus, which is not
suitable for mounting in Zone 0 or Zone 1, but with field connections suitable for connection
to suitable equipment which is mounted in Zone 0 or Zone 1. The products have been
approved for this purpose by EC-Type Examination certificates which have been issued by
an ATEX Notified Body, namely Baseefa.