turck excom remote-i/o for non-ex & ex areas · field instrumentation. the modular sys-tem...

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excom® Remote-I/o foR non-ex and ex aReas

D300395 2013/08

*D300395ßß0813*

Hans Turck GmbH & Co. KGWitzlebenstr. 745472 Muelheim an der Ruhr GermanyTel. +49 208 4952-0Fax +49 208 4952-264E-Mail [email protected] www.turck.com

WoRldWIde HeadquaRteRs

Your Global

automation Partner!

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

https://www.clrwtr.com/Catalog/Manufacturers/TURCK/Connectivity/Field-Wireable-Connectors

The company

The company

TURCK is one of the leading manufactur-ers in industrial automation. With more than 3.350 employees in 27 countries as well as sales partners in further 60 states, we are always close to you. As a special-ist in sensor, fieldbus, connection and in-terface technology as well as human-ma-chine interfaces (HMI) and RFID, we offer

efficient solutions for factory and process automation. With our state-of-the-art production facilities in Germany, Switzer-land, the USA, Mexico and China we, as a family-owned company, are able to react quickly and flexibly to the demands of local markets.

The product portfolio

Whether applied in machine and plant construction, in the sectors of auto-motive, transport and handling, food and beverage or in the chemical or phar-maceutical industry, TURCK automation solutions and products increase the availability and efficiency of your sys-tems. Moreover, our efficiently stand-ardized products help you to cut down

on costs for purchase, storage, installa-tion and operational safety. We provide you with optimal solutions for your auto-mation lines. This is possible thanks to the industry-specific know-how we have acquired in close co-operation with our customers and through electronics de-velopment and production on the high-est level.


Our service

With nearly 50 years of experience and extensive know-how, we support you in each phase of the project, from a first analysis up to tailor-made solutions and commissioning of your application. Our priority is, to continuously enhance the efficiency and productivity of your pro-

duction processes and machines. With the excellent quality of our products, the support of our specialists and our fast delivery service, your systems will always run to the highest possible capacity.

The company

The product data base

Whether software tools for program-ming, configuration or commissioning support, our data sheets or CAD data are available in 80 export formats. On our website you find prod-ucts and solutions fast, seven days a

week, at any place worldwide and in nine different languages. You have ac-cess to nearly all products and solu tions – clearly structured, completely docu-mented and free for download.


Table of contents

excom® – Remote-I/O system for non-Ex and Ex areas

excom® is a remote-I/O system intended for use in Ex and non-Ex areas. The user not only profits from components that are optimized for these zones, but also from a standard concept to configure and parametrize the periphery and the field instrumentation. The modular sys-tem provides bus-compatible remote-I/O modules in IP20 for connection of binary and analog intrinsically safe and non-safe field devices. Depending on the de-ployed periphery, the system‘s Ex- pro-tection rating enables installation in zones 1 and 2. The field circuits are ap-proved for use in zone 0. Essential com-ponents of the modular system are pow-er supplies, gateways and I/O modules as well as the module racks for the compo-nents. The backplane is integ rated in the module racks. The backplane contains the connection layer for the field devices, from where power is distributed and data is transferred. The supply modules provide the entire system with power.

All modules are easily arranged: The gateways, power supply and I/O mod-ules are simply plugged on the module rack. All internal connections are thus es-tablished; only the periphery has to be connected. All modules can be plugged and removed in ongoing opera tion (hot swapping). The system auto matically checks whether the new module match-es the defined slot assign ment.

The excom® DTM (Device Type Manager) enables the user to operate the peri-phery and the field instrumentation di-rectly via the PROFIBUS network - inde-pendent from the higher level Master Class 1 control system. The integrated system-scan functionality makes com-missioning even faster and more failsafe. excom® also supports the connection of HART®-capable field devices. This allows continuous HART® communication via PROFIBUS-DPV1 up to the PLC; also auxil-iary HART® variables can be transmitted cyclically via DPV0 communication.


Table of contents

Overview system installation Page 8

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Standard system features Page 10

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Solutions for the Ex area Page 12

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Solutions for the non-Ex area Page 66

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System enclosures Page 102

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Accessories for the remote-I/O system Page 104

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Basics of explosion protection Page 108

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excom® – Remote-I/O system

excom® Remote-I/O – One system for all zones

The excom® remote-I/O system allows the user to freely select the location of installation. It can be installed in zones 1 and 2 and in the non-Ex area. The user not only profits from components that are optimized for these zones, but also from a standard concept to configure and parametrize the periphery and the field instrumentation. If this system is in-

stalled in zones 1 and 2, you can use our special power supply modules that gen-erate the intrinsically safe system volt-age. The interface to the fieldbus, here it is PROFIBUS-DP, is also intrinsic ally safe. A new module rack allows to operate up to 24 I/O modules in the non- Ex area and in zone 2, which further reduces the ba-sic costs for installation.

Plug and Play – also in ongoing operation

Hot swapping makes the excom® system a particularly user-friendly system: The system can be serviced and changed at any time. The I/O modules – including the power supply modules – can be plugged and unplugged in ongoing op-

eration, even in zone 1, without disturb-ing the field communication. This in-creases plant availability and saves time during commissioning and exten sion of system.

DTM-based – Online parametrization and configuration

With the new excom® -DTM and the ad-vanced gateway communication, the user can easily operate the periphery and the field instrumentation at any time via the PROFIBUS-network, with or with-out the higher-level Master Class 1 con-trol system. With the help of an FDT- frame such as PACTware™ all systems available on the PROFIBUS can be scanned and copied to the project tree

of the frame application. Then all peri-pheral modules and HART® field devices will be available online to the operator. The entire field wiring can thus be checked and the HART® field devices with their associated DTM diagnosed and configured. In this way, the field in-stallation is validated, before being transferred to the control system.



HART® – consistently parametrized from the PLC down to the field devices

excom® takes advantage of the world-wide applied HART® communication and allows field devices to be HART®-para-metrized via bus. The system transmits process and diagnostic data of the peri-phery and communicates, if necessary, with the HART® field instrumentation. This gives the control system additional

information on process values, diagnosis and asset management directly in digital form. Since the communication protocol allows the transmission of data over al-ready installed lines, the user can build, service and maintain the „last mile“ with little effort.

High availability – Redundant power supply and communication

The remote-I/O system excom® from TURCK has proven its worth in the pro-cess industry and the related high de-mands on equipment safety. The system allows a fully redundant setup of the power supply as well as of the communi-cation interfacing. Either 24 VDC or 230 VAC power supply is possible. As a standard feature, excom® also provides a

system-redundancy solu tion for the bus structure. This allows the redundant excom® system to be connected via re-dundant bus physics to a process control system with a PROFIBUS master. Thanks to the open standard, the redundancy system can be operated with any master available on the market.

System enclosure – Fieldbus system with full approval

TURCK offers an enclosure concept for the entire excom® system. The enclos ures are made of rugged stainless steel, fea-ture ignition protection type Ex-e and al-low installation in zone 1. In order to save the user the trouble of getting ap-provals for each system component, TURCK has obtained a single system ap-

proval for the stainless steel enclos ures with integrated module rack. All compo-nents used have been individu ally tested and approved. This makes customized solutions possible. Assembly and instal-lation take place at TURCK in order to en-sure that the required clear ance and creepage distances are met.



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excom® – Solutions for the Ex area

The excom® series allows the user to free-ly select the location of installation. It can be installed in zones 1 and 2 and in the non-Ex area. The user not only profits from components that are optimized for these zones, but also from an integrated concept for configuration and paramet-rization of the periphery and the field in-strumentation. A uniform Ex-i peri phery supports the processing of signals and the control of field devices from the zones 0, 1 and 2. If this periphery is in-stalled in zone 1 and 2, you can use our special power supply modules that gen-erate the intrinsically safe system volt-age, in order to capture the signals as

close as possible to the instrumentation. The interface to the fieldbus, here it is PROFIBUS-DP, is also intrinsically safe. Because of its configuration, the entire system can be services in ongoing opera-tion when installed in the Ex area. The enclosures used so far in zone-2 excom® installations, now have free space avail-able for additional components such as valve terminals or load switches. Since a special gateway safeguards the Ex-i peri-phery against the bus, a separate seg-ment coupler is not needed to imple-ment the intrinsically safe RS485-IS bus physics.


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Type Ident no. Signal Function Page

DM80EX 6884006 DX I/O module, digital, 8-channel 14

DF20EX 6884061 DF frequency module, 2-channel 16

DI40EX 6884004 DI input module, digital, 4-channel 18

DO401EX 6884203 DO output module, digital, 4-channel 20

AI401EX 6884204 AI input module, analog, 4-channel 22

AI41EX 6884020 AI input module, analog, passive, 4-channel 24

AI43EX 6884137 AI potentiometer module, 4-channel 26

AO401EX 6884205 AO output module, analog, 4-channel 28

AIH40EX 6884001 AIH input module, analog, active, 4-channel, HART® 30

AIH41EX 6884005 AIH input module, analog, passive, 4-channel, HART® 32

AOH40EX 6884003 AOH output module, analog, 4-channel, HART® 34

TI40EX 6884000 TI input module, temperature, 4-channel 36

TI41EX 6884190 TI input module, temperature, 4-channel 38

GDP-IS/FW2.2 6884210 PROFIBUS-DP interface 40

GDP-NI/FW2.2 6884225 PROFIBUS-DP interface 42

PSD24EX 6881721 power supply module, 24 VDC, zone 1 44

PPSA230EX 6900293 converter, 230 VAC 46

PPSA115EX 6900294 converter, 115 VAC 48

PSM24-3G 6881722 power supply unit, 24 VDC, zone 2 50

MT-PPS 9100516 Upstream subrack for PPSA 52

MT18-R024 9100438 module rack, zone 1, for 16 modules 54

MT16-3G 9100681 module rack, zone 2, for 16 modules 56

MT24-3G 9100682 module rack, zone 2, for 24 modules 58

SC12EX 6884047 PROFIBUS-DP segment coupler 60

OC11Ex/2G.2 6890427 PROFIBUS-DP optocoupler for zone 1 62

OC11Ex/3G.2 6890428 PROFIBUS-DP optocoupler for zone 2 64


excom® – Remote-I/O systemModules for intrinsically safe circuits

I/O module, digital, 8-channel

The I/O module DM80Ex is used for the connection of NAMUR sensors (DIN EN 60 60947-5-6) and actuators. When wire- break or short-circuit monitoring are activated, mechanical contacts can only be connected with a corresponding resistor circuitry (WM1, Ident no. 0912101).

The module features protection class Ex ib IIC and can be mounted in zone 1 in combination with excom®.

The explosion protection category of in-puts/ outputs is Ex ia IIC.

When connecting the fieldbus devices, care has to be taken that all inputs and outputs share a common potential.

Input and output mode can be adjusted via the PROFIBUS-DP master. The follow-ing parameters can be adjusted: switch-ing behaviour, switch-on delay, substi-tute value, wire-break and short circuit monitoring.

The user can furthermore determine whether an input or an output should be provided at the connecting point. The following configurations are possi-ble: 8 inputs/0 outputs; 6 inputs/2 out-puts up to 0 inputs/8 outputs (GSD- file, Mode 2). This guarantees optimal adap-tation to the corresponding application environment.

I/O module for NAMUR sensors and actuators

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Technical data

Modules for intrinsically safe circuits excom® – Remote-I/O system

Type DM80EXIdent no. 6884006

Supply voltage via the backplanes, central power supplyPower consumption ≤ 1 WGalvanic separation to int. bus and supply circuitNumber of channels 8-channel

Input circuits acc. to EN 60947-5-6 (NAMUR),intrinsically safe acc. to EN 60079-11

No-load voltage 8 VDCShort-circuit current 4 mASwitching threshold on/off type 1.8 mA / 1.4 mA mASwitching frequency ≤ 100 HzShort circuit < 367 ΩWire-break < 0.2 mA

Output circuits for intrinsically safe actuatorsNo-load voltage 8 VDCRated current 4 mAInternal resistance Ri 320 ΩSwitching frequency ≤ 100 HzShort circuit < 367 ΩWire-break < 0.2 mA

Ex approval acc. to conformity certificate

PTB 00 ATEX 2178

Device designation É II 2 (1) G Ex ib [ia] IIC T4É II (1) D [Ex ia IIIC]

Max. values: terminal connection 1+2 / 3+4Max. output voltage Uo ≤ 9.6 VMax. output current Io ≤ 44 mAMax. output power Po ≤ 106 mWCharacteristic linearInternal inductance/capacitance Li /Ci

Li negligibly smallCi negligibly small

External inductance/capacitance Lo /Co

IIC IIBLo [mH] Co [µF] Co [µF]2.0 0.9 5.11.0 1.1 6.10.5 1.3 7.30.2 1.7 8.6

Indication Operational readiness 1 x green / redState/ Fault 8 x yellow / red

Housing material plasticConnection mode module, plugged on rackProtection class IP20Ambient temperature -20…70 °CRelative humidity ≤ 95% at 55 °C acc. to EN 60068-2Vibration test acc. to IEC 60068-2-6Shock test acc. to IEC 60068-2-27EMC acc. to EN 61326 1 (2006)

acc. to NAMUR NE21 (2007)MTTF 141 years acc. to SN 29500 (Ed. 99) 40 °CDimensions 18 x 118 x 103 mm



Frequency module, 2-channel

The input module DF20EX is equipped with 8 channels according to NAMUR, which are divided into two blocks. There is one frequency input per block and three control inputs/outputs.

The module features protection class Ex ib IIC and can be mounted in zone 1 in combination with excom®. When con-necting the fieldbus devices, care has to be taken that all inputs and outputs

share a common potential. The explo-sion protection category of inputs/ out-puts is Ex ia IIC.

The module can be used as a counter or a frequency module: It is thus suited for pulse counting of binary input signals or frequency measurements of binary pulse sequences of NAMUR sensors.

The counting direction can either be set externally via a control input or internal-ly by setting a parameter. The maximum frequency of one block is 4 kHz; with 2 blocks the frequency is reduced to 2 kHz.

Input and output mode can be adjusted via the PROFIBUS-DP master. Each chan-nel is equipped with parametrizable wire-break/short-circuit monitoring.

Frequency module for the connection of intrinsically safe sensors (according to NAMUR)

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Type DF20EXIdent no. 6884061




Measuring accuracy ≤ 0.1 % of full scale


PTB 00 ATEX 2178


Max. values: terminal connection 1+2 / 3+4Max. output voltage Uo ≤ 9.6 VMax. output current Io ≤ 44 mAMax. output power Po ≤ 106 mWCharacteristic linearInternal inductance/capacitance Li /Ci









Input module, digital, 4-channel

The input module DI40Ex is designed for the connection of NAMUR sensors (DIN EN 60947-5-6) or mechanical contacts.

When wire-break or short-circuit moni-toring are activated, mechanical con-tacts can only be connected with a cor-responding resistor circuitry (WM1, Ident no. 0912101).

The module features protection class Ex ib IIC and can be mounted in zone 1 in combination with excom®. The explo-sion protection category of the inputs is Ex ia IIC. The inputs are galvanically sep-arated from each other.

The behaviour of the inputs can be ad-justed via the PROFIBUS-DP master. The following parameters can be adjusted: switching behaviour, switch- on delay, substitute value, wire-break and short circuit monitoring.

Input module for intrinsically safe sensors

Complete galvanic separation

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Type DI40EXIdent no. 6884004

Supply voltage via the backplanes, central power supplyPower consumption ≤ 1 WGalvanic separation complete galvanic separation acc. to

EN 60079-11Number of channels 4-channel




PTB 02 ATEX 2032

Device designation É II 2 (1GD) G Ex ib [ia] IIC T4Max. values: terminal connection 1+2Max. output voltage Uo ≤ 8.7 VMax. output current Io ≤ 9.6 mAMax. output power Po ≤ 21 mWCharacteristic linearInternal inductance/capacitance Li /Ci

Li negligibly smallCi ≤ 10.0 nF


IIC IIBLo [mH] 2.0 5.0Co [µF] 1.2 5.2






Output module, digital, 4-channel

The output module DO401Ex is de-signed for connection of intrinsically safe actuators such as valves or indicators.

The module features protection class Ex ib IIC and can be mounted in zone 1 in combination with excom®. The explosion protection category of the inputs is Ex ia IIC. The outputs are galvanically separat-ed from each other.

One actuator per channel can be con-nected. The choice of connection ena-bles two intrinsically safe circuits with different Ex-data per channel.

Please see the load curve for the valve control values. Please refer to the Ex- ap-proval of the valve manufacturer for the admissible limit values.

The following output values are sup-ported for example:

22.5 V / 5 mA 19.0 V / 15 mA 16.0 V / 25 mA 14.0 V / 35 mA 12.0 V / 45 mA

Output module for intrinsically safe actuators


Load curve terminal pair 1+2


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Type DO401EXIdent no. 6884203

Supply voltage via the backplanes, central power supplyPower consumption ≤ 4.5 WGalvanic separation complete galvanic separation acc. to


Output circuits for intrinsically safe actuatorsSwitching frequency ≤ 50 HzShort circuit ï 50 mAWire-break < 1 mA


PTB 10 ATEX 2024


Max. values: Terminal connection 1+2Max. output voltage Uo ≤ 25 VMax. output current Io ≤ 80 mAMax. output power Po ≤ 750 mWCharacteristic angularEx-inflexion point Ue /Ie 18.2 V / 41.2 mAInternal inductance/capacitance Li /Ci



IIC IIBLo [mH] Co [nF] Co [nF]2.0 — 3501.0 — 4100.5 — 5000.2 — 6600.1 110 820

Max. values: Terminal connection 3+4Max. output voltage Uo ≤ 19 VMax. output current Io ≤ 100 mAMax. output power Po ≤ 710 mWCharacteristic angularEx-inflexion point Ue /Ie 13.0 V / 53.4 mAInternal inductance/capacitance Li /Ci



IIC IIBLo [mH] Co [nF] Co [nF]2.0 — 10001.0 130 10000.5 140 10000.2 170 1100






Input module, analog, 4-channel

The input module AI401Ex is designed to connect 2-wire transducers (active in-put = source mode / transducer passive) and 4-wire transducers (passive input = sink mode / transducer active).

The module features protection class Ex ib IIC and can be mounted in zone 1 in combination with excom®. The field cir-cuits feature protection class Ex ia IIC resp. Ex iaD.

The field circuits are galvanically sepa-rated from each other.

HART®-compatible transducers can be connected to the module. The field de-vice can thus be parametrized directly at the terminals on the DIN rail with a li-censed modem. An additional imped-ance in the circuit is not necessary.

The measuring range is digitized in the scope of 0…21 mA. For clear reading, the digitized value is spread to 0 … 21000 (independent of the para-metrized measuring range) and trans-mitted to the host system.

Input module for the connection of passive transmitters (active inputs) or active transmitters (passive inputs).


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Type AI401ExIdent no. 6884204



Input circuits intrinsically safe acc. to EN 60079-110/4…20 mA

Supply voltage 15 VDC at 20 mAOverload capability > 21 mALow level control < 3.6 mAShort circuit > 24 mA (only with live zero)Wire-break < 2 mA (only with live zero)

Resolution 14 BitLinearity deviation ≤ 0.05 % full scaleTemperature drift ≤ 0.005 % / KRise time/fall time ≤ 50 ms (10 … 90 %)Max. measurement tolerance under EMC influence

≤ 0.1 %


PTB 03 ATEX 2217

Device designation É II 2 (1) G Ex ib [ia] IIC T4É II (1) D [Ex iaD]

Max. values: terminal connection 1+2Max. output voltage Uo ≤ 19.1 VMax. output current Io ≤ 90 mAMax. output power Po ≤ 615 mWInternal resistance Ri 304 ΩCharacteristic trapezoidalInternal inductance/capacitance Li /Ci



IIC IIBLo [mH] 0.20 1.0Co [nF] 170 960

Max. values: Terminal connection 3+4Max. output voltage Uo ≤ 6 VMax. output current Io ≤ 2.5 mAMax. output power Po ≤ 4 mWCharacteristic linear

Internal inductance/capacitance Li /Ci



IIC IIBLo [mH] 10 20Co [nF] 1900 8600

Indication Operational readiness 1 x green / redState/ Fault 4 x red





Input module, analog, passive, 4-channel

The input module AI41Ex is designed to connect 4-wire transducers (passive in-put = sink mode / transducer active).

The module features protection class Ex ib IIC and can be mounted in zone 1 in combination with excom®. The explo-sion protection category of the inputs is Ex ia IIC.

The inputs are galvanically separated from each other.

The resolution is 14 bit, i.e. the analog value between 0…21 mA is represented as a number between 0 and 16383. For clear reading, the digitized value is spread to 0 … 21000 and transmitted to the host system. For transmission to the

host system, voltage is indicated as a value in a range between 0…10000.

Input module for the connection of active transmitters (passive inputs)


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Type AI41EXIdent no. 6884020

Supply voltage via the backplanes, central power supplyPower consumption ≤ 1 WGalvanic separation complete galvanic separation acc. to



Overload capability > 22 mALow level control < 3.6 mAShort circuit < 5 V (only with live zero)Wire-break < 2 mA (only with live zero)

Resolution 14 BitLinearity deviation ≤ 0.1 % full scaleTemperature drift ≤ 0.005 % / KRise time/fall time ≤ 50 ms (10 … 90 %)


PTB 03 ATEX 2023

Device designation É II 2 (1GD) G Ex ib [ia] IIC T4Max. values: terminal connection 1+2Max. output voltage Uo ≤ 6.6 VMax. output current Io ≤ 2.1 mAMax. output power Po ≤ 3.5 mWCharacteristic linearInternal inductance/capacitance Li /Ci



IIC IIBLo [mH] Co [µF] Co [µF]2.0 2.0 111.0 2.3 120.5 2.7 150.2 3.3 19

Max. values: terminal connection 3+4Max. output voltage Uo ≤ 6.6 VMax. output current Io ≤ 2.1 mAMax. output power Po ≤ 3.5 mWCharacteristic linear










Potentiometer module, 4-channel

The analog input module AI43Ex is de-signed for the connection of potentiom-eters in 3 or 4-wire technology. If 3-wire potentiometers are used, the terminals at the module rack have to be bridged. Resistance measurements, hence the analysis of potentiometers with a 2-wire connection, are not possible.

The module has four field circuits to control 3 or 4-wire potentiometers. The field circuits are galvanically separated from the power supply, from the inter-

nal bus and from each other. The mod-ule features protection class Ex ib IIC and can be mounted in zone 1 in combi-nation with excom®. The explosion pro-tection category of the inputs is Ex ia IIC.

Each potentiometer input is monitored for wire-break, whereby single as well as multiwire-break of the four connection lines per input is reliably detected. Short-circuit monitoring is not carried out. In case of a line error, the para-metrized substitute value is immediately

output and the output value is set to ‚in-valid-bit‘. This state is maintained until valid measured values are provided again.

The resolution is 14 bit. For clear read-ing, 0…100% is spread to the digitized value 0 … 10000 (independent of the parametrized measuring range) and transmitted to the host system.

Input module for the connection of potentiometers


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Type AI43EXIdent no. 6884137



Input circuits intrinsically safe acc. to EN 60079-11potentiometer

Nominal resistance 400 Ω … 12 kΩ



PTB 06 ATEX 2026

Device designation É II 2 (1GD) G Ex ib [ia] IIC T4Max. values: terminal connection 1-4Max. output voltage Uo ≤ 6.6 VMax. output current Io ≤ 25 mAMax. output power Po ≤ 42 mWCharacteristic linearInternal inductance/capacitance Li /Ci

Li negligibly smallCi ≤ 150 nF


IIC IIBLo [mH] Co [µF] Co [µF]5.0 1.6 8.51.0 2.2 12






Output module, analog, 4-channel

The output module AO401Ex is de-signed for connection of intrinsically safe analog actuators such as control valves or process indicators.

The module features protection class Ex ib IIC and can be mounted in zone 1 in combination with excom®. The explo-sion protection category of the outputs is Ex ia IIC resp. Ex iaD.

The outputs are galvanically separated from each other.


The host system transmits a digitized control value 0…21000 (independent of the parametrized measuring range). This raw value is then transformed by the AO401Ex into a signal between 0…21 mA.

Output module for the connection of analog actuators


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Type AO401ExIdent no. 6884205



Output circuits intrinsically safe acc. to EN 60079-110/4…20 mA

No-load voltage 16 VDCExternal load ≤ 640 ΩShort circuit < 50 Ω (only with live zero)Wire-break < 2 mA (only with live zero)


≤ 0.1 %


PTB 00 ATEX 2179

Device designation É II 2 (1) G Ex ib [ia] IIC T4É II (1) D [Ex iaD]

Max. values: terminal connection 1+2Max. output voltage Uo ≤ 18.9 VMax. output current Io ≤ 80 mAMax. output power Po ≤ 510 mWInternal resistance Ri 334 ΩCharacteristic trapezoidalInternal inductance/capacitance Li /Ci









Input module, analog, active, 4-channel, HART®

The input module AIH40Ex is designed to connect 2-wire transducers (active in-put = source mode / transducer passive).


The inputs are not galvanically separat-ed from each other. When connecting the field devices, care has to be taken

that all inputs share a common potential.

HART®-compatible sensors connected to the module communicate with the inte-grated HART® controller.

The resolution is 14 bit, i.e. the analog value between 0…21 mA is represented as a number between 0 and 16383. For clear reading, the digitized value is spread to 0 … 21000 and transmitted to the host system.

Up to 8 HART® variables (max. 4 per channel) can be read via the cyclical PROFIBUS data traffic. The bidirectional exchange of variables between the host system and the HART® transmitter is im-plemented via PROFIBUS-DPV1.

Parameters like wire-break or short- cir-cuit monitoring, measuring range, HART® communication etc., can be ad-justed for each channel separately and are solely initialized by the PROFIBUS master.

Input module for connection of 2-wire transmitters

Transmission of HART® data

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Type AIH40EXIdent no. 6884001



Supply voltage 15 VDC at 22 mAHART® Impedance > 240 ΩOverload capability > 22 mALow level control < 3.6 mAShort circuit < 5 V (only with live zero)Wire-break < 2 mA (only with live zero)


≤ 0.1 % for shielded signal cable≤ 1 % for unshielded signal cable


PTB 00 ATEX 2059 X


Max. values: terminal connection 1+2Max. output voltage Uo ≤ 22.1 VMax. output current Io ≤ 93 mAMax. output power Po ≤ 640 mWCharacteristic trapezoidalInternal inductance/capacitance Li /Ci

Li ≤ 0.22 mHCi ≤ 1.1 nF


IIC IIBLo [mH] 0.5 2.0Co [nF] 65 270






Input module, analog, passive, 4-channel, HART®

The input module AIH41Ex is designed to connect 4-wire transducers (passive input = sink mode / transducer active).


The inputs are not galvanically separat-ed from each other. When connecting the field devices, care has to be taken that all inputs share a common potential.

HART®-compatible sensors connected to the module communicate with the HART® controller.


Up to 8 HART® variables (max. 4 per channel) can be read via the cyclical PROFIBUS data traffic. The bidirectional exchange of variables between the host

system and the HART® transmitter is im-plemented via PROFIBUS-DPV1.




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Type AIH41EXIdent no. 6884005



HART® Impedance > 240 ΩOverload capability > 22 mALow level control < 3.6 mAShort circuit < 5 V (only with live zero)Wire-break < 2 mA (only with live zero)




PTB 00 ATEX 2059 X


Max. values: terminal connection 3+4Max. output voltage Uo ≤ 7.2 VMax. output current Io ≤ 16 mAMax. output power Po ≤ 29 mWCharacteristic linearInternal inductance/capacitance Li /Ci

Li ≤ 0.11 mHCi ≤ 1.1 nF


IIC IIBLo [mH] 0.39 1.89Co [nF] 63.9 268






Output module, analog, 4-channel, HART®

The output module AOH40Ex is de-signed for connection of intrinsically safe analog actuators such as control valves or process indicators.


The outputs are not galvanically sepa-rated from each other. When connect-ing the field devices, care has to be tak-en that all outputs share a common potential.

HART®-compatible actuators connected to the module communicate directly with the HART® controller.

The resolution is 13 bit, i.e. the analog value of 0…21 mA is represented as a

number between 0 and 8191. For easier operation, the host system operates in a value range between 0…21000. This raw value is reduced by the AOH40EX to a 13-bit resolution.

Parameters such as line monitoring, sub-stitute value etc. can be adjusted for each channel separately and are initial-ized solely by the master.



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Type AOH40EXIdent no. 6884003


Output circuits intrinsically safe acc. to EN 60079-110/4…20 mA

No-load voltage 16 VDCHART® Impedance > 240 ΩExternal load ≤ 600 ΩShort circuit < 50 Ω (only with live zero)Wire-break > 15 V (only with live zero)




PTB 02 ATEX 2051


Max. values: terminal connection 1+2Max. output voltage Uo ≤ 22.1 VMax. output current Io ≤ 93 mAMax. output power Po ≤ 640 mWCharacteristic trapezoidalInternal inductance/capacitance Li /Ci

Li ≤ 0.22 mHCi ≤ 1.1 nF


IIC IIBLo [mH] 0.5 2Co [nF] 65 270






Input module, temperature, 4-channel

The input module TI40Ex is used for the connection of 2, 3 and 4-wire tempera-ture probes of the types Pt100, Pt200, Pt500, Pt1000, Ni100 and Cu100, as well as for the connection of thermocouples of the types B, E, D, J, K, L, N, R, S, T and U. The module can also be used for the measurement of low voltages (-75…+75 mV, -1.2…+1.2 V) and resistance measurements (0…30 Ω, 0…300 Ω, 0…3 kΩ)

The module features protection class Ex ib IIC and can be mounted in zone 1 in combination with excom®. The explo-

sion protection category of the inputs is Ex ia IIC.

Line compensation of 2-wire tempera-ture resistors is done by means of para-metrized resistance values. These values have to be determined first through measurements.

When using thermocouples, external cold junction compensation can be car-ried out separately for each channel by connecting resistors such as the Pt100 to the two unused terminals. Internal compensation instead is parametrized

for all channels via an integrated Pt100 resistor.

The internal resolution is 16 bit, the analog value is represented as a number between 0 and 32767 on the PROFIBUS- DP. The temperature is indicated in Kel-vin. For conversion to °C, please observe an offset of 273.2.


Input module for the connection of temperature probes


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Type TI40ExIdent no. 6884000

Supply voltage via module rack, central power supply module

Power consumption ≤ 1 WGalvanic separation complete galvanic separation acc. to


Input circuits intrinsically safe acc. to EN 60079-11Pt100Pt200Pt500Pt1000Ni100Cu100thermocouple

Resolution 16 BitLinearity deviation ≤ 0.05 % measuring rangeTemperature drift ≤ 0.005 % / KRise time/fall time ≤ 1.3 s (10 … 90 %)Max. measurement tolerance under EMC influence



PTB 00 ATEX 2181


Max. values: passive transducer connectionMax. output voltage Uo ≤ 5.5 VMax. output current Io ≤ 25 mAMax. output power Po ≤ 35 mWCharacteristic linearInternal inductance/capacitance Li /Ci

Li negligibly smallCi ≤ 60.0 nF



Max. values: active transducer connectionMax. output voltage Uo ≤ 1.2 VMax. output current Io ≤ 50 mAMax. output power Po ≤ 60 mWCharacteristic rectangular




IIC IIBLo [mH] Co [µF] Co [µF]2.0 1.6 9.81.0 1.9 120.5 2.3 140.2 3.0 19







The input module TI41Ex is used for the connection of the 2, 3 and 4-wire tem-perature probes Pt100, Ni100 and Cu100.


Line compensation of 2-wire tempera-ture resistors is done by means of para-metrized resistance values. These values have to be determined first through measurements.

The analog resistance value is digitized to 16-bit. The temperature is given in Kelvin, the resolution in 0.1 K steps. For conversion to °C, please observe an off-set of 273.2.


11

12

13

14

21

22

24

31

34

RTH-4L

11

12

13

14

RTH-4L

RTH-3L

RTH-2L

11

12

13

14

21

22

23

24

31

32

33

34

41

42

43

44

channel 1

channel 2

channel 3

channel 4

terminal configuration connection possibilities (selectable)

Input module for the connection of RTDs (resistance thermo detectors)


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Technical data


Type TI41ExIdent no. 6884190




Input circuits intrinsically safe acc. to EN 60079-11Pt100Ni100Cu100

Resolution 16 BitLinearity deviation ≤ 0.01 % measuring rangeTemperature drift ≤ 0.002 % / KRise time/fall time ≤ 50 ms (10 … 90 %)Max. measurement tolerance under EMC influence

≤ 0.1 % for shielded signal cable≤ 0.5 % for unshielded signal cable


PTB 13 ATEX 2014


Max. values: passive transducer connectionMax. output voltage Uo ≤ 5.3 VMax. output current Io ≤ 4.5 mAMax. output power Po ≤ 6 mWCharacteristic linearInternal inductance/capacitance Li /Ci

Li ≤ 2.0 mHCi ≤ 1.0 µF





excom® – Remote-I/O systemGateway for installation in zones 1 and 2

PROFIBUS-DP interface

The GDP-IS gateway serves to connect the excom® system to PROFIBUS-DP net-works. Connection to the PROFIBUS- DP is established via optical fibers or copper cables. When using optical fibers for data transfer an optocoupler pair must be installed between wired and optical PROFIBUS which also adapts the level to the IS layer. When using copper cables a segment coupler (RS485-IS coupler) must be installed to ensure explosion protection.

The gateway can be operated at a maxi-mum transmission rate of 1500 kBaud. The bus is connected to a standard min-iature SUB-D slot on the module rack.

A GSD file containing all configuration files and parameter sets is available for system configuration. When connected to suitable host systems, you can change the system configuration during operation.

The gateway provides the entire range of PROFIBUS diagnostic functions in-cluding port-related diagnostics. Addi-tionally, manufacturer-specific error codes are generated. These can be HART® communication errors, power supply errors, planning errors as well as information on simulators, internal com-munication and redundancy status.

Redundancy: The use of two gateways and two bus cables ensures error-free communication, in case one gateway or one bus line may fail. If one of the com-ponents fails, the other immediately takes over (module racks MT18… only), this is called line redundancy. System re-dundancy (two masters, each with its own segment coupler connected to a gateway) is also supported.

Recommended wiring components: PROFIBUS‐DP cable, type 451B D9T‐RS485IS male Segment coupler SC12Ex Optocoupler OC11Ex/…

Intrinsically safe gateway for PROFIBUS- DPV1

Connection of the excom® station to the PROFIBUS-DP networks

Baud rate max. 1.5 Mbaud PROFIBUS interface acc. to PROFIBUS

user organization (PNO) with RS485-IS layer

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Gateway for installation in zones 1 and 2 excom® – Remote-I/O system

Type GDP-IS/FW2.2Ident no. 6884210



EN 60079-11

Transmission rate 9.6 kbps up to 1.5 MbpsAddressing range 1 … 99


PTB 09 ATEX 2013

Device designation É II 2 G Ex ib IIC T4Max. values: RS485-IS fieldbus connectionMax. output voltage Uo ≤ 3.6 VMax. output current Io ≤ 125 mAMax. output power Po ≤ 112.5 mWCharacteristic linearMax. input voltage Ui ≤ 4.2 V

Indication Operational readiness 1 x green / redInt. communication (CAN) 1 x yellow / redExt. Communication (PDP) 1 x yellow / redRedundancy readiness (PRIO) 1 x yellow / redError indication 1 x red



External RS485 fieldbus system: protection type Ex ib IIC highest value of each terminal pair: Ui = 4.2 V highest value of the terminal pairs: ∑ Ii = 4.8 A cables type A resp. B acc. to EN 60079‐25 with the following assignments:L’/R’ ≤ 15 µH/Ω C’ ≤ 250 nF/km Ø strand ≥ 0.2 mm massed inductances and capacitances in the external fieldbus system are not permitted


excom® – Remote-I/O systemGateway for installation in the safe area


The GDP-NI gateway serves to connect the excom® system to PROFIBUS-DP net-works. Connection to the PROFIBUS- DP is established via optical fibers or copper cables. When using optical fibers for data transfer, an optocoupler pair must be installed between wired and optical PROFIBUS.


A GSD file containing all configuration files and parameter sets is available for system configuration. When connected to suitable host systems, you can change the system configuration during operation.

The gateway provides the entire range of PROFIBUS diagnostic functions in-cluding port-related diagnostics. Addi-tionally, manufacturer-specific error codes are generated. For example HART® communication errors, power supply errors, planning errors as well as information on simulators, internal com-munication and redundancy status.

Redundancy: The use of two gateways and two bus cables ensures error-free communication, in case one gateway or one bus line may fail. If one gateway fails, the other takes over smoothly, this is called line redundancy. System redun-dancy (two masters, each connected to a gateway) is also supported.

Recommended wiring components: PROFIBUS‐DP cable, type 451 D9T‐RS485 male

PROFIBUS-DPRS485

excom®

Master

Host Gateway for PROFIBUS‐DPV1

communication Connection of the excom® station to

the PROFIBUS-DP networks Baud rate max. 1.5 Mbaud PROFIBUS interface acc. to PROFIBUS

user organization (PNO)

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Technical data

Gateway for installation in the safe area excom® – Remote-I/O system

Type GDP-NI/FW2.2Ident no. 6884225


Power consumption ≤ 1 WGalvanic separation complete galvanic separation



PTB 13 ATEX 2013 X

Device designation É II (2) G [Ex ib] IIC



acc. to NAMUR NE21 (2007)MTTF acc. to SN 29500 (Ed. 99) 40 °CDimensions 18 x 118 x 103 mm


excom® – Remote-I/O systemPower supply module for installation in zone 1

Power supply module, 24 VDC, zone 1

The PSD24Ex module supplies the excom® system with power to the full ex-tension. A combined protection rating of Ex-m, Ex-e and Ex-i enables applica-tion in zone 1. It is also fully potted and installed in a die-cast aluminium enclosure.

The PSD24Ex supplies 24 VDC.

The external power supply is plugged on the module rack via Ex-e clamps. Any contact with the clamps under power should be avoided. They are located be-low the closure cap. Switch of power be-fore contact!

Redundancy: Two power supply mod-ules can be installed together with an appropriate module rack. In case of power cut or failure of one device, the second unit provides the power for the whole system. Different potentials can be used for power supply.

PSD24Ex PSD24Ex

+–

PE24 VDC

+–

PE24 VDC

DC power module for supply of a fully assembled module rack in zone 1

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Power supply module for installation in zone 1 excom® – Remote-I/O system

Type PSD24EXIdent no. 6881721

Nominal voltage 24 VDCOperating voltage range 19.2…32 VDCPower consumption ≤ 66.5 WPower supply output ≤ 60 WGalvanic separation galvanically separated input and output

circuit, rated voltage 60 V


PTB 00 ATEX 2193

Device designation É II 2 G Ex eb mb [ib] IIC T4

Indication Operational readiness 1 x greenSupply voltage 1 x green

Electrical connection via backplaneTerminal cross-section 2.5 mm2 flexible / 4.0 mm2 rigid

Housing material aluminiumConnection mode flange, 4 x M4 screwsProtection class IP50Ambient temperature -20…70 °CRelative humidity ≤ 95% at 55 °C acc. to EN 60068-2Vibration test acc. to IEC 60068-2-6Shock test acc. to IEC 60068-2-27EMC acc. to EN 61326 1 (2006)




Converter, 230 VAC

The AC/DC converter PPSA230Ex sup-plies the excom® system with power to the full extension. A combined protec-tion rating of Ex-m and Ex-e enables ap-plication in zone 1. It is also fully potted and installed in a die-cast aluminium enclosure.

The PPSA230Ex supplies 230 VAC.


Redundancy: Two power supply mod-ules can be installed with an appropriate module rack. In case of power cut or fail-ure of one device, the second unit pro-vides the power for the whole system. Different potentials can be used for power supply.

PPSA PPSA

+–

+–

LNPE

VAC

LNPE

VAC

AC/DC converter for AC supply of DC power supply module

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Technical data


Type PPSA230EXIdent no. 6900293

Nominal voltage 230 VACOperating voltage range 200…250 VACPower consumption ≤ 75 VAPower supply output ≤ 66.5 WGalvanic separation galvanically separated input and output



PTB 04 ATEX 2047

Device designation É II 2 G Ex e m IIC T4






Converter, 115 VAC

The AC/DC converter PPSA115Ex sup-plies the excom® system with power to the full extension. A combined protec-tion rating of Ex-m and Ex-e enables ap-plication in zone 1. It is also fully potted and installed in a die-cast aluminium enclosure.

The PPSA115Ex supplies 115 VAC.



PPSA PPSA

+–

+–

LNPE

VAC

LNPE

VAC

AC/DC converter for AC supply of DC power supply module

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Technical data


Type PPSA115EXIdent no. 6900294

Nominal voltage 115 VACOperating voltage range 100…125 VACPower consumption ≤ 75 VAPower supply output ≤ 66.5 WGalvanic separation galvanically separated input and output



PTB 04 ATEX 2047

Device designation É II 2 G Ex e m IIC T4






Power supply unit, 24 VDC, zone 2

The PSM24-3G module supplies the excom® system with power to the full ex-tension. The power supply module can be used in zone 2.

The PSM24-3G supplies 24 VDC.



PSM24

+

–24 VDC

+

–24 VDC

DC power module for supply of a fully assembled module rack in zone 2

Features


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Technical data


Type PSM24-3GIdent no. 6881722




PTB 12 ATEX 2009

Device designation É II 3 (2) G Ex nAc ic [ib] IIC T4

Indication Operational readiness 1 x greenError indication 1 x red





excom® – Remote-I/O systemModule rack for installation in zone 1

Upstream subrack for PPSA

The module rack MT-PPS consists of a backplane and the actual rack system. It can accommodate two AC converters for the supply of downstream connect-ed 24 VDC module racks.

To plug and unplug AC converters pow-er has to be switched off first. (Do not work on connecting terminals prior to removing the AC converters).

A combined protection rating of Ex-e and Ex-q enables application in zone 1.

The rack system is made of strand-cast aluminium, providing better stability and shielding. It is suitable for wall mounting and fits in the system enclosures.

Upstream connected subrack for up to 2 AC/DC converters

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Technical data

Module rack for installation in zone 1 excom® – Remote-I/O system

Type MT-PPSIdent no. 9100516


PTB 04 ATEX 2091 X

Device designation É II 2 G Ex eb IIC T4

AC converter 2

Housing material aluminium, strand-castConnection mode wall mountingProtection class IP20Ambient temperature -20…70 °CRelative humidity ≤ 95% at 55 °C acc. to EN 60068-2Vibration test acc. to IEC 60068-2-6Shock test acc. to IEC 60068-2-27EMC acc. to EN 61326 1 (2006)

acc. to NAMUR NE21 (2007)MTTF 1211 years acc. to SN 29500 (Ed. 99)

40 °CDimensions 110 x 260 x 130 mm



Module rack, zone 1, for 16 modules

The MT18-R024 module rack consists of a backplane and the actual rack system. It can accommodate 2 gateways, 2 pow-er supply modules as well as 16 I/O modules. Up to 128 binary inputs/ out-puts or 64 analog inputs/outputs resp. a mix of both can be connected to it.

All modules can be plugged and un-plugged under power without interrupt-

ing the data transfer. The same applies to redundant gateways and power sup-ply modules.

A combined protection rating of Ex-e and Ex-i enables application in zone 1.

The power supply of modules on the backplane is limited to prevent sparking. This allows you to pull and plug mod-

ules in powered state with excom® mounted in zone 1.


Module rack for max. 16 I/O modules, 2 gateways and 2 power supply modules

The terminals for the signal connec-tion level are available as accessories

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Technical data


Type MT18-R024Ident no. 9100438


PTB 00 ATEX 2194 U

Device designation É II 2 (1) G Ex eb ib [ia] IIC

DC power supply 2Gateway 2I/O modules 16

Bus connection 2 x 9-pol. D-SUBBus address 3 x decimally coded rotary switches

Electrical connection 4 x 4 clamps per moduleTerminal cross-section 1.5 mm2







The module rack MT16-3G consists of a backplane and the actual rack system. It can accommodate 2 gateways, 2 power supply modules as well as 16 I/O mod-ules. Up to 128 binary inputs/ outputs or 64 analog inputs/outputs resp. a mix of both can be connected to it.









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Technical data


Type MT16-3GIdent no. 9100681


PTB 00 ATEX 2194 U

Device designation É II 3 (1) G Ex nAc ib ic [ia] IIC T4


Bus connection 2 x 9-pol. D-SUBBus address 2 x decimal-coded rotary switches














The module rack is made of strand-cast aluminium, providing better stability and shielding. It is suitable for wall mounting and fits in the system enclosures.



Features


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Technical data


Type MT24-3GIdent no. 9100682


PTB 00 ATEX 2194 U

Device designation É II 3 (1) G Ex nAc ib ic [ia] IIC T4








excom® – Remote-I/O systemPROFIBUS network components

PROFIBUS-DP segment coupler

The PROFIBUS-DP segment coupler SC12Ex from TURCK has been devel-oped for intrinsically safe PROFIBUS connection.

Equipped with one RS485 and two RS485-IS interfaces, this coupler is suited for many Ex-area applications. The RS485-IS interface is entirely realized ac-cording to the PNO PROFIBUS guideline. The coupler can thus supply both lines of the TURCK Ex-Remote I/O system excom® simultaneously (line redundan-cy). Just one device is required for Ex-separation and line redundancy.

The segment coupler SC12Ex is IP20 rat-ed, suited for mounting in the non-Ex area and can be supplied redundantly. Both power supply inputs are decou-pled by diods. The load distribution de-pends on the level of operating voltage. Operating voltage 18…32 VDC.

In switch position 0, the coupler identi-fies the baud rate automatically. Addi-tionally, the start-delimiter occurences of the PROFIBUS telegrams are evaluat-ed. Three consecutive and valid start-de-limiter occurences have to be received before identification locks in.

All received telegrams are checked for plausibility by means of start-delimiter sequences. Baud rate detection is start-ed after reset. If telegrams are not re-ceived within 1.7 seconds, baud rate search is activated. Alternatively, the baud rate can be adjusted via rotary switch.

In order not to limit the number of nodes and cable length of a PROFIBUS- DP segment, amplitude and phase are reproduced in the coupler. The user can choose between capacitive and direct earthing.

Device for intrinsically safe separation of RS485 and RS485-IS

Connection of max. 62 bus nodes (31 in redundant mode)

Redundant power supply Automatic baud rate detection

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Technical data

PROFIBUS network components excom® – Remote-I/O system

Type SC12EXIdent no. 6884047

Nominal voltage 24 VDCOperating voltage range 18…32 VDCCurrent consumption < 200 mAGalvanic separation complete galvanic separation acc. to


Transmission rate 9.6 kbps up to 1.5 Mbps


PTB 03 ATEX 2115

Device designation É II (2) GD [Ex ib] IICMax. values: RS485-IS Sub-D connectionMax. output voltage Uo ≤ 3.71 VMax. output current Io ≤ 129 mAMax. output power Po ≤ 120 mWCharacteristic linearMax. input voltage Ui ≤ 4.2 V

Indication Operational readiness 2 x greenState/ Fault 3 x yellow / redBaude rate detection 1 x yellow

Housing material aluminium, anodizedFront plate FR4, grey / blueConnection mode snap-fit on DIN rail (DIN 60715)Protection class IP20Ambient temperature -20…70 °CRelative humidity ≤ 95% at 55 °C acc. to EN 60068-2Vibration test acc. to IEC 60068-2-6Shock test acc. to IEC 60068-2-27EMC acc. to EN 61326 1 (2006)

acc. to NAMUR NE21 (2007)MTTF 106 years acc. to SN 29500 (Ed. 99) 40 °CDimensions 142 x 105.5 x 31 mm



PROFIBUS-DP optocoupler for zone 1

The optocoupler OC11Ex/2G.2 converts the PROFIBUS-DP signals into optical signals. They are then transferred safely and undisturbed over long distances via optical fibers from the non-Ex to the Ex area.

The OC11Ex/3G.2 in zone 2 transmits the signals via the optical interface to the OC11Ex/2G.2 in zone 1 which con-verts them. The signals are then output intrinsically safe at the RS485-IS interface.

The RS485-IS interface is entirely real-ized according to the PNO PROFIBUS

guideline. The optocoupler OC11Ex/ 2G.2 is equipped with intrinsically safe RS485-IS PROFIBUS

interface (acc. to the RS485-IS draft worked out by the PNO work group)

intrinsically safe optical interface with ST connectors for emitter and receiver

Up to 31 bus nodes can be connected to the optocoupler. Baud rates of 9.6 kbps up to 1.5 Mbps are possible rep. auto-matically detected.

Four status LEDs indicate power ON, fib-er-optic segment, RS485 interface and baud rate. The device features an M8

communication interface. Two OC11Ex devices can be coupled together via the M8 interface. Wire- break and short-cir-cuit are not transmitted from one seg-ment to the next one. All segments can thus be operated trouble-free and inde-pendently of one another.

In order not to limit the number of nodes and cable length of a PROFIBUS- DP segment, amplitude and phase are reproduced in the coupler. The OC11Ex/ 2G.2 shield is always capacitively cou-pled to equipotential bonding.

DP-V1-Master

OC11Ex/3G

RS485

Slave

RS485-IS

excom®

OC11Ex/2G

Slave

DP-connector

DP-connector with integratedterminating resistor

Non-Ex-area

Ex-area zone 1

max. distancebetween thefibre-optic couplers 2,5 km

fibre-optic connection

Ex-area zone 2

Device for data transfer between elec-trical and optical fieldbus circuits

Power supply of max. 31 nodes Mounting in zone 1 possible Note: Idle level corresponds to active

light!

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Technical data


Type OC11Ex/2G.2Ident no. 6890427





PTB 05 ATEX 2051 X

Device designation É II 2 G Ex e mb ib [ib op is] IIC T4Max. values: RS485-IS Sub-D connectionMax. output voltage Uo ≤ 3.64 VMax. output current Io ≤ 127 mAMax. output power Po ≤ 116 mWCharacteristic linearMax. input voltage Ui ≤ 4.2 V


Housing material aluminium, anodizedFront plate FR4, greyConnection mode snap-fit on DIN rail (DIN 60715) or wall

mountingProtection class IP20Ambient temperature -20…70 °CRelative humidity ≤ 95% at 55 °C acc. to EN 60068-2Vibration test acc. to IEC 60068-2-6Shock test acc. to IEC 60068-2-27EMC acc. to EN 61326 1 (2006)




PROFIBUS-DP optocoupler for zone 2

The optocoupler OC11Ex/3G.2 converts the PROFIBUS-DP signals into optical signals. They are then transferred safely and undisturbed over long distances via optical fibers from the non-Ex to the Ex area.

The optocoupler can be installed in the non-Ex area or in zone 2. The OC11Ex/ 3G.2 receives the PROFIBUS-DP signals at its standard interface RS485 and transmits them via the intrinsically safe optical interface to the optocoupler OC11Ex/2G.2 in zone 1.

The optocoupler OC11Ex/3G.2 is equipped with RS485 interface – standard PROFIBUS-

DP interface with RS485 level acc. to EIA 485 (the control cable for direction control is not connected)

intrinsically safe optical interface with ST connectors for emitter and receiver

Up to 31 bus nodes can be connected to the optocoupler. Baud rates of 9.6 kbps up to 1.5 Mbps are possible rep. auto-matically detected.

Four status LEDs indicate power ON, fib-er-optic segment, RS485 interface and

baud rate. The device features an M8 communication interface. Two OC11Ex devices can be coupled together via the M8 interface. Wire- break and short-cir-cuit are not transmitted from one seg-ment to the next one. All segments can thus be operated trouble-free and inde-pendently of one another.

In order not to limit the number of nodes and cable length of a PROFIBUS- DP segment, amplitude and phase are reproduced in the coupler. The user can choose between capacitive and direct earthing.

DP-V1-Master

OC11Ex/3G

RS485

Slave

RS485-IS

excom®

OC11Ex/2G

Slave

DP-connector

DP-connector with integratedterminating resistor

Non-Ex-area

Ex-area zone 1

max. distancebetween thefibre-optic couplers 2,5 km

fibre-optic connection

Ex-area zone 2

Device for data transfer between elec-trical and optical fieldbus circuits

Power supply of max. 31 nodes Mounting in zone 2 possible Note: Idle level corresponds to active

light!

Features


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Technical data


Type OC11Ex/3G.2Ident no. 6890428





PTB 05 ATEX 2052 X

Device designation É II (2) G [Ex ib op is] IIC


PTB 05 ATEX 2053 X

Device designation É II 3 G Ex nA II T4


Housing material aluminium, anodizedFront plate FR4, greyConnection mode snap-fit on DIN rail (DIN 60715) or wall

mountingProtection class IP20Ambient temperature -20…70 °CRelative humidity ≤ 95% at 55 °C acc. to EN 60068-2Vibration test acc. to IEC 60068-2-6Shock test acc. to IEC 60068-2-27EMC acc. to EN 61326 1 (2006)




excom® – Solutions for the non-Ex area

The excom® series allows the user to free-ly select the location of installation. It can be installed in zones 1 and 2 and in the non-Ex area. The user not only profits from components that are optimized for these zones, but also from a standard concept to configure and parametrize the periphery and the field instrumenta-tion. The periphery which is used in the Ex area can also be used in the non-Ex area. A new module rack allows to oper-ate up to 24 I/O modules in the non- Ex

area, which further reduces the basic costs for installation. Since TURCK has developed a special power supply mod-ule for this application, the whole system is much more compact. Even with pure non-Ex applications the user benefits from the further development of the excom® series – especially with regard to digital outputs: A relay output is now ad-ditionally available, with which outputs up to 0.5 A can be switched.


Solu

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for t

heno

n-Ex

area


Type Ident no. Signal Function Page

DM80-N 6884211 DX I/O module, digital, 8-channel 68

DF20-N 6884212 DF frequency module, 2-channel 70

DI40-N 6884213 DI input module, digital, 4-channel 72

DO40-N 6884214 DO output module, digital, 4-channel 74

DO60R-N 6884196 DO relay module, 6-channel 76

AI40-N 6884215 AI input module, analog, 4-channel 78

AI41-N 6884216 AI input module, analog, passive, 4-channel 80

AI43-N 6884217 AI potentiometer module, 4-channel 82

AO40-N 6884218 AO output module, analog, 4-channel 84

AIH40-N 6884219 AIH input module, analog, active, 4-channel, HART® 86

AIH41-N 6884220 AIH input module, analog, passive, 4-channel, HART® 88

AOH40-N 6884221 AOH output module, analog, 4-channel, HART® 90

TI40-N 6884222 TI input module, temperature, 4-channel 92

TI41-N 6884223 TI input module, temperature, 4-channel 94

GDP-N /FW2.2 6884224 PROFIBUS-DP interface 96

PSM24-N 6881723 power supply unit, 24 VDC, non-Ex 98

MT24-N 9100683 module rack, non-Ex, for 24 modules 100


excom® – Remote-I/O systemModules for non-Ex circuits

I/O module, digital, 8-channel

The I/O module DM80-N is used for the connection of NAMUR sensors (DIN EN 60947-5-6) and actuators. When wire- break or short-circuit monitoring are activated, mechanical contacts can only be connected with a corresponding resistor circuitry (WM1, Ident no. 0912101).

When connecting the fieldbus devices, care has to be taken that all inputs and outputs share a common potential.

Input and output mode can be adjusted via the PROFIBUS-DP master. The follow-ing parameters can be adjusted: switch-ing behaviour, switch-on delay, substi-tute value, wire-break and short circuit monitoring.

The user can furthermore determine whether an input or an output should be provided at the connecting point. The following configurations are possi-ble: 8 inputs/0 outputs; 6 inputs/2 out-puts up to 0 inputs/8 outputs (GSD- file, Mode 2). This guarantees optimal adap-tation to the corresponding application environment.

I/O module for NAMUR sensors and actuators

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Type DM80-NIdent no. 6884211


Input circuits acc. to EN 60947-5-6 (NAMUR)No-load voltage 8 VDCShort-circuit current 4 mASwitching threshold on/off type 1.8 mA / 1.4 mA mASwitching frequency ≤ 100 HzShort circuit < 367 ΩWire-break < 0.2 mA

Output circuits for low-power actuatorsNo-load voltage 8 VDCRated current 4 mAInternal resistance Ri 320 ΩSwitching frequency ≤ 100 HzShort circuit < 367 ΩWire-break < 0.2 mA






Frequency module, 2-channel

The input module DF20-N is equipped with 8 channels acc. to NAMUR, which are grouped together in two blocks. There is one frequency input per block and three control inputs/outputs.

The module can be used as a counter or frequency module: It is thus suited for

pulse counting of binary input signals or for frequency measurements of binary pulse sequences of NAMUR sensors.

The counting direction can either be set externally via a control input or internal-ly by setting a parameter. The maximum frequency of one block is 4 kHz; with 2

blocks the frequency is reduced to 2 kHz.

Input and output mode can be adjusted via the PROFIBUS-DP master. Each chan-nel is equipped with parametrizable wire-break/short-circuit monitoring.

Frequency module for the connection of NAMUR sensors

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Type DF20-NIdent no. 6884212



Measuring accuracy ≤ 0.1 % of full scale






Input module, digital, 4-channel

The input module DI40-N is designed for the connection of NAMUR sensors (DIN EN 60947-5-6) or mechanical contacts.

When wire-break or short-circuit moni-toring are activated, mechanical con-

tacts can only be connected with a cor-responding resistor circuitry (WM1, Ident no. 0912101).


The behaviour of the inputs can be ad-justed via the PROFIBUS-DP master. The following parameters can be adjusted: switching behaviour, switch- on delay, substitute value, wire-break and short circuit monitoring.

Input module for NAMUR sensors Complete galvanic separation

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Type DI40-NIdent no. 6884213

Supply voltage via the backplanes, central power supplyPower consumption ≤ 1 WGalvanic separation complete galvanic separationNumber of channels 4-channel







Output module, digital, 4-channel

The output module DO40-N is used for connection of low-power actuators such as valves or indicators.


One actuator per channel can be con-nected. Via selection of connecting ter-minals, two circuits per channel are made available with different supply data.

Please see the load curve, showing the connection values for valve control.

The following output values are sup-ported for example:

22.5 V / 5 mA 19.0 V / 15 mA 16.0 V / 25 mA 14.0 V / 35 mA 12.0 V / 45 mA

+

–

+

–

+

–

+

–

11

12

13

14

21

22

23

24

31

32

33

34

41

42

43

44

U = 8…24 V

U = 10…18 V

U = 10…18 V

U = 8…24 V

channel 1

channel 2

channel 3

channel 4


Output module for low-power actuators




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Type DO40-NIdent no. 6884214

Supply voltage via the backplanes, central power supplyPower consumption ≤ 4.5 WGalvanic separation complete galvanic separationNumber of channels 4-channel

Output circuits for low-power actuatorsNo-load voltage 24 VDCInternal resistance Ri 300 ΩSwitching frequency ≤ 50 HzShort circuit ï 50 mAWire-break < 1 mA






Relay module, 6-channel

The relay module DO60R-N is used for connection of non-intrinsically safe ac-tuators such as valves or indicators.

The outputs are designed as zero- poten-tial relay contacts. 2 x changeover contacts (channel 1

and 2) 4 x NO contacts (channel 3 to 6)

The channels 3/4 and 5/6 are separately

switchable to changeover function. For this, an external bridge at the terminals is needed.

Note: To protect the module rack, the contact circuits inside the DO60R-N module are safeguarded by fuses (1 AT). The module must be replaced after tripping the fus-es. The connections 12-13 and 22-23 are

not further protected and should maxi-mally be loaded with the switching cur-rent of a relay contact. Use preferably terminal 12 resp. 22 for connection.

Status and error messages of the single outputs and the module are indicated via LEDs at the front.

NO

COM

COM

NC

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12

13

14

21

22

23

24

31

32

33

34

41

42

43

44

NO

COM

COM

NC

NO

COM

NO

COM

NO

COM

NO

COM

channel 1

channel 2

channel 3

channel 5

channel 4

channel 6

terminal configuration connection possibilities

Relay output for higher switching capacity

NO/NC configurable output Configurable as 4 x changeover

contacts Configurable as 6 x NO contacts

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Type DO60R-NIdent no. 6884196


Output circuits 6 x relays (2 x changeover contacts, 4 x NO)

Switching voltage ï 12 VUC … ≤ 60 VUCSwitching current ï 10 mA

≤ 1 A (60 VAC / 30 VDC)≤ 0.7 A (60 VDC)






Input module, analog, 4-channel

The input module AI40-N is used for the connection of 2-wire transducers (active input = source mode / transducer pas-sive) or 4-wire transducers (passive in-put = sink mode / transducer active).

The field circuits are galvanically sepa-rated from each other.


The measuring range is digitized in the scope of 0…21 mA. For clear reading, the digitized value is spread to 0…21000 (independent of the para-metrized measuring range) and trans-mitted to the host system.

Input module for the connection of passive transmitters (active inputs) or active transmitters (passive inputs).


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Type AI40-NIdent no. 6884215


Input circuits 0/4…20 mASupply voltage 15 VDC at 20 mAOverload capability > 21 mALow level control < 3.6 mAShort circuit > 24 mA (only with live zero)Wire-break < 2 mA (only with live zero)


≤ 0.1 %

Max. output current Io ≤ 2.5 mAMax. output power Po ≤ 4 mW






Input module, analog, passive, 4-channel

The input module AI41-N is used for the connection of 4-wire transducers (pas-sive input = sink mode / transducer active).


The resolution is 14 bit, i.e. the analog value between 0…21 mA is represented as a number between 0 and 16383. For clear reading, the digitized value is spread to 0…21000 and transmitted to the host system. For transmission to the

host system, voltage is indicated as a value in a range between 0…10000.

Input module for the connection of active transmitters (passive inputs)


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Input circuits 0/4…20 mAOverload capability > 22 mALow level control < 3.6 mAShort circuit < 5 V (only with live zero)Wire-break < 2 mA (only with live zero)







Potentiometer module, 4-channel

The analog input module AI43-N is used for the connection of potentiometers in 3 or 4-wire technology. If 3-wire potenti-ometers are used, the terminals at the module rack have to be bridged. Resist-ance measurements, hence the analysis of potentiometers with a 2-wire connec-tion, are not possible.

The module has four field circuits to control 3 or 4-wire potentiometers. The

field circuits are galvanically separated from the power supply, from the inter-nal bus and from each other.

Each potentiometer input is monitored for wire-break, whereby single as well as multiwire-break of the four connection lines per input is reliably detected. Short-circuit monitoring is not carried out. In case of a line error, the para-metrized substitute value is immediately

output and the output value is set to ‚in-valid-bit‘. This state is maintained until valid measured values are provided again.

The resolution is 14 bit. For clear read-ing, 0…100 % is spread to the digitized value 0…10000 (independent of the parametrized measuring range) and transmitted to the host system.

Input module for the connection of potentiometers


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Input circuits potentiometerNominal resistance 400 Ω … 12 kΩ







Output module, analog, 4-channel

The output module AO40-N is used for connection of analog actuators such as control valves or process indicators.



The host system transmits a digitized control value 0…21000 (independent of the parametrized measuring range). This raw value is then transformed by the AO40 -N into a value between 0…21 mA.



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Type AO40-NIdent no. 6884218


Output circuits 0/4…20 mANo-load voltage 16 VDCExternal load ≤ 640 ΩShort circuit < 50 Ω (only with live zero)Wire-break < 2 mA (only with live zero)


≤ 0.1 %






Input module, analog, active, 4-channel, HART®

The input module AIH40-N is used for the connection of 2-wire transducers (active input = source mode/transducer passive).


HART®-compatible sensors connected to the module communicate with the inte-grated HART® controller.






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Type AIH40-NIdent no. 6884219


Input circuits 0/4…20 mASupply voltage 15 VDC at 22 mAHART® Impedance > 240 ΩOverload capability > 22 mALow level control < 3.6 mAShort circuit < 5 V (only with live zero)Wire-break < 2 mA (only with live zero)








Input module, analog, passive, 4-channel, HART®

The input module AIH41-N is used for the connection of 4-wire transducers (passive input = sink mode / transducer active).


HART®-compatible sensors connected to the module communicate with the HART® controller.






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Type AIH41-NIdent no. 6884220


Input circuits 0/4…20 mAHART® Impedance > 240 ΩOverload capability > 22 mALow level control < 3.6 mAShort circuit < 5 V (only with live zero)Wire-break < 2 mA (only with live zero)








Output module, analog, 4-channel, HART®

The output module AOH40-N is used for connection of analog actuators such as control valves or process indicators.

The outputs are not galvanically sepa-rated from each other. When connect-ing the field devices, care has to be tak-en that all outputs share a common potential.

HART®-compatible actuators connected to the module communicate directly with the HART® controller.

The resolution is 13 bit, i.e. the analog value of 0…21 mA is represented as a number between 0 and 8191. For easier operation, the host system operates in a value range between 0…21000. This

raw value is reduced by the AOH40-N to a 13-bit resolution.




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Type AOH40-NIdent no. 6884221


Output circuits 0/4…20 mANo-load voltage 16 VDCHART® Impedance > 240 ΩExternal load ≤ 600 ΩShort circuit < 50 Ω (only with live zero)Wire-break > 15 V (only with live zero)









The input module TI40-N is used for the connection of 2, 3 and 4-wire tempera-ture probes of the types Pt100, Pt200, Pt500, Pt1000, Ni100 and Cu100, as well as for the connection of thermocouples of the types B, E, D, J, K, L, N, R, S, T and U. The module can also be used for the measurement of low voltages (-75…+75 mV, -1.2…+1.2 V) and resistance meas-urements (0…30 Ω, 0…300 Ω, 0…3 kΩ).

Line compensation of 2-wire tempera-ture resistors is done by means of para-

metrized resistance values. These values have to be determined first through measurements.

When using thermocouples, external cold junction compensation can be car-ried out separately for each channel by connecting resistors such as the Pt100 to the two unused terminals. Internal compensation instead is parametrized for all channels via an integrated Pt100 resistor.

The resolution is 16 bit, i.e. the analog value is represented as a number be-tween 0 and 65535. The temperature is indicated in Kelvin. For conversion to °C, please observe an offset of 273.2.


Input module for the connection of temperature probes


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Type TI40-NIdent no. 6884222


Power consumption ≤ 1 WGalvanic separation complete galvanic separationNumber of channels 4-channel

Input circuits Pt100Pt200Pt500Pt1000Ni100Cu100thermocouple

Resolution 16 BitLinearity deviation ≤ 0.05 % measuring rangeTemperature drift ≤ 0.005 % / KRise time/fall time ≤ 1.3 s (10 … 90 %)Max. measurement tolerance under EMC influence








The input module TI41-N is used for the connection of the 2, 3 and 4-wire tem-perature probes Pt100, Ni100 and Cu100.

Line compensation of 2-wire tempera-ture resistors is done by means of para-

metrized resistance values. These values have to be determined first through measurements.

The analog resistance value is digitized to 16-bit. The temperature is given in Kelvin, the resolution in 0.1 K steps. For

conversion to °C, please observe an off-set of 273.2.


11

12

13

14

21

22

24

31

34

RTH-4L

11

12

13

14

RTH-4L

RTH-3L

RTH-2L

11

12

13

14

21

22

23

24

31

32

33

34

41

42

43

44

channel 1

channel 2

channel 3

channel 4


Input module for the connection of RTDs (resistance thermo detectors)


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Type TI41-NIdent no. 6884223


Power consumption ≤ 1 WGalvanic separation complete galvanic separationNumber of channels 4-channel

Input circuits Pt100Ni100Cu100

Resolution 16 BitLinearity deviation ≤ 0.01 % measuring rangeTemperature drift ≤ 0.002 % / KRise time/fall time ≤ 50 ms (10 … 90 %)Max. measurement tolerance under EMC influence

≤ 0.1 % for shielded signal cable≤ 0.5 % for unshielded signal cable





excom® – Remote-I/O systemGateway for the non-Ex system


The GDP-N gateway serves to connect the excom® system to PROFIBUS-DP net-works. Connection to the PROFIBUS- DP is established via optical fibers or copper cables. When using optical fibers for data transfer, an optocoupler pair must be installed between wired and optical PROFIBUS.


A GSD file containing all configuration files and parameter sets is available for

system configuration. When connected to suitable host systems, you can change the system configuration during operation.

The gateway provides the entire range of PROFIBUS diagnostic functions in-cluding port-related diagnostics. Addi-tionally, manufacturer-specific error codes are generated. For example HART® communication errors, power supply errors, planning errors as well as information on simulators, internal com-munication and redundancy status.

Redundancy: The use of two gateways and two bus cables ensures error-free communication, in case one gateway or one bus line may fail. If one of the com-ponents fails, the other immediately takes over (module racks MT18… only), this is called line redundancy. System re-dundancy (two masters, each with its own segment coupler connected to a gateway) is also supported.

Recommended wiring components: PROFIBUS‐DP cable, type 451 D9T‐RS485 male

PROFIBUS-DPRS485

excom®

Master

Host Gateway for PROFIBUS‐DPV1

communication Connection of the excom® station to

the PROFIBUS-DP networks Transmission rate max. 1.5 Mbps PROFIBUS interface acc. to PROFIBUS

user organization (PNO) with RS485-IS layer

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Gateway for the non-Ex system excom® – Remote-I/O system

Type GDP-N /FW2.2Ident no. 6884224


Power consumption ≤ 1 WGalvanic separation to int. bus and supply circuit






excom® – Remote-I/O systemPower supply module for the non-Ex system

Power supply unit, 24 VDC, non-Ex

The PSM24-N unit supplies the excom® system with power to the full extension. The power supply module can only be used in non-Ex areas.

The PSM24-N supplies 24 VDC.

The external power supply is connected via clamps on the module rack. The clamps should not be contacted under power. They are located below a closure cap. Switch of power before contact!


PSM24

+

–24 VDC

+

–24 VDC

DC power module for supply of a fully assembled module rack in non-Ex areas

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Power supply module for the non-Ex system excom® – Remote-I/O system

Type PSM24-NIdent no. 6881723



Indication Operational readiness 1 x greenError indication 1 x red





excom® – Remote-I/O systemModule rack for the non-Ex system

Module rack, non-Ex, for 24 modules


All modules can be plugged and un-plugged under power without interrupt-ing the data transfer. The same applies to redundant gateways and power sup-ply modules.

The module rack can only be used in non-Ex areas for non-Ex signals.

The module rack is made of strand-cast aluminium, providing better stability and shielding. It is suitable for wall mounting and fits in the system enclosures.



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Module rack for the non-Ex system excom® – Remote-I/O system

Type MT24-NIdent no. 9100683









EG-VA 65 55 26 / 1 1 1 – 02 0 0 / …

EG-VA System enclosure

System enclosureEG-VA excom® system enclosure,

stainless steel

65 55 26 Dimensions /

Depth26 Housing depth in cm

Height55 Housing height in cm

Width65 Housing width in cm

1 Material

Material0 stainless steel 1.43011 stainless steel 1.4404

1 Viewing Window

Viewing Window0 without viewing window1 without viewing window

1 Hole pattern –

Hole pattern0 dummy plate1 flange plate M162 flange plate M203 special design and number

02 Module rack

Module rack

00 no module rack02 module rack MT16-2G05 module rack MT16-3G06 module rack MT24-3G09 module rack MT24-N

0 Upstream sub-rack

Upstream sub-rack

0 without upstream sub-rack MT-PPS1 with upstream sub-rack MT-PPS

0 Segment coupler /

Segment coupler0 without installed OC11 segment

coupler1 with installed OC11 segment

coupler2 with two installed OC11 segment

couplers

… Special number

Special number… special number for all extra fitments

such as trace heating, circuit breaker, fuses or lightning components

Type code of system enclosure


The system enclosures of the EG-VA6555 series have a module rack integrated with either 16 or 24 available slots. They are made of stainless steel, feature igni-tion protection class Ex-e and can be in-stalled in zone 1. They even resist the se-verest environmental conditions. In order to save the user the trouble of get-ting approvals for each system compo-nent, TURCK has obtained a single sys-tem approval. All components used have been individually tested and ap-proved. The user can also configure the systems according to individual de-mands. Assembly and installation take place at TURCK in order to ensure that the required clearance and creepage dis-tances are met.

Features

Stainless steel enclosures with inte-grated module rack

Enclosure door with integrated in-spection window

Integrated module rack MT…, con-nection terminals (see accessories)

Flange plate equipped with cable glands

Dimensions (w x h x d): Type 460 x 550 x 260 [mm] Type 650 x 550 x 260 [mm] Type 800 x 550 x 260 [mm]

Syst

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OC11-LINKCABLE Extension cable to connect two identical OC11Ex devices (2G i.e. 3G), length 0.24 m

D9T-RS485 PROFIBUS bus connector for RS485, Fast Connect, without PG gland, 35° outlet

D9T-RS485PG PROFIBUS bus connector for RS485, Fast Connect, with PG gland, 35° outlet

D9T-RS485IS PROFIBUS bus connector for RS485-IS, Fast Connect, only for use with IS devices!

excom® – Remote-I/O-SystemAccessories for the remote-I/O system


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STB16-4RS/1,5-BU Set 16 pcs.: 4-pin terminal block, screw clamps blue

STB16-4RC/1,5-BU Set 16 pcs.: 4-pin terminal block, cage clamps blue

STB16-4RS/1,5-BK Set 16 pcs.: 4-pin terminal block, screw clamps black

STB16-4RC/1,5-BK Set 16 pcs.: 4-pin terminal block, cage clamps black


ELST-M20EX Pressure compensation element (plastic), prevents condensation inside the housing

ELVA-M20EX Pressure compensation element (stainless steel), prevents condensation inside the housing

SK8 Terminal for shield connection to bus bars

BM-PS Closure cap for redundant power supply slot, zone 1



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BM1 Dummy module for free slots on the module rack, version 1

BM-N Dummy module for free slots on the module rack, version N

Modex switching terminal

Switching terminal for manual switching in Ex areas (enable function for downstream connected devices)

Modex isolating relay Isolating relay for the connection of non-intrinsically safe circuits (e.g. Ex e valves with auxiliary voltage)


Basics of explosion protectionTerms and definitions

Directives and standards

History

Until the end of 1975, numerous national directives covering the field of explosion protection existed in the individual European states. On 18 December 1975, the first framework directive on ex-plosion protection above ground came into effect, applying in the member states of the European Union: 76/117/EWG.

Until 1990, the directive 76/117/EWG was modified several times. The different national directives were directly related to stan-dards that applied exclusively to electrical equipment and to ex-plosion protection above ground. The fact that national directi-ves were still in effect restricted free trade in this area.

In the beginning of 1994, the ”Framework Directive 94/9/EC of the European Parliament and Council of 23 March 1994 on the approximation of the laws of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres” was passed. This directive has regard to the ”European Treaty” of 1985, in particular article 100a (amend-ment of 2 February 1992), establishing the European Community. „ATEX 100a“ is the common shortcut for it and is derived from the French ”atmosphère explosible“ (explosive atmosphere). In addition to article 100a, there are further articles which are in progress of being transposed into directives. Whenever the ATEX directive is quoted in our TURCK documentation, reference is made to the new directive of explosion protection ATEX 100a.

Within the member states of the European Union the ATEX 100a was translated into national legislation, e.g. in the Federal Repub-lic of Germany by the ”Gerätesicherheitsgesetz (§11 GSGV)” – since 1 December 2011 „ Produktsicherheitsgesetzt (§34 ProdSG) and the ”Explosionsschutzverordnung (EXVO) (11. ProdSV)”.

The national directives applying for explosion protection were valid until 30.06.2003. The ATEX 100a came into force on the 01.07.2003 and has been updated and renamed to ATEX 95a.

Efforts to harmonize the explosion protection directives on inter-national level, resulted in the establishment of the IEC 60079. The pursuit towards free trade worldwide was the leading motive for it. In a first step, the IECEx framework was defined, fixing the con-ditions of approval for devices. Furthermore a quality manage-ment system is stipulated which is binding for the manufacturer.

Installation and operation of electrical equipment in hazar-dous areas – standards and regulations

Involved with installation, acceptance and operation of electrical equipment are:

The legislator having industrial supervision, trade organiza-tions, TÜV and experts as supervisory authorities.

All plant personnel are required to observe strict guidelines such as health and safety and other work regulations that govern the main tenance and operation of electrical equipment located in the hazardous area.

Plant builders who must meet safety requirements according to EN 60079-14, (RL 1999/92/EG), ATEX 137.

The manufacturers of components bound by constructional re-quirements set forth by IEC/EN 60079 resp. ATEX 95a (RL 94/9/EG).

EN 60079-14 resp. DIN VDE 0165 – Installation of electrical equipment in explosion hazardous areas

The DIN VDE 0165 includes the safety requirements that must be observed (e. g. identification and classification of explosion ha-zardous locations, temperature classes, cable routing, require-ments for the installation of electrical devices in zones 0, 1 and 2, many specific provisions). Contrary to the standards described above, which are primarily for manufacturers, this standard ap-plies to plant builders, operators and test personnel.

The rules for interconnection derive from the installation regula-tions acc. to IEC 60079-14 or rather EN 60079-14. According to these, the safety-related maximum values of the equipment‘s in-put and output parameters must be compared in order to evalua-te if several inter connected devices with intrinsically safe circuits comply with the demands on intrinsic safety.

BetrSichV – Industrial safety regulations

The industrial safety regulations BetrSichV provides information about the safety and health protection of work equipment and their intended use. Furthermore BetrSichV regulates the operati-onal safety of systems requiring monitoring and the organization of health and safety of workers.

ATEX 137 – Directive for system operators

The directive 1999/92/EC of the European Parliament and Council of 16 December concerning the essential health and safety require ments is intended to guard workers against the potential hazards of an explosive atmosphere (formerly ATEX 118, now ATEX 137). It is directed at system operators and employers and contains binding regulations. Among other things, this stipulates the assessment of risks resulting from a potentially explosive at-mosphere, the keeping of areas exposed to potentially explosive atmospheres and the keeping of an explosion protection document.


Basic

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Terms and definitionsBasics of explosion protection

ExVO – Explosion protection directive

The ExVO regulates the placing on the market of devices, protec-tive systems and components intended for use in potentially ex-plosive atmospheres and is the German transposition of the di-rective 94/9/EC. It describes the essential health and safety requirements and mandatory conformity assessment procedures. The ExVO is thus mainly aimed at manufacturers of devices, main-tenance and test personnel.

Like the directive 94/9/EC, ExVO excludes the following equip-ment from its scope (summarised): Medical devices, explosive substances, or unstable chemicals, personnel protection equip-ment, seagoing vessels, offshore systems and products for milita-ry purposes.

EN 60079-0 – Electrical equipment for use in explosion hazar-dous areas, general requirements

EN 60079-0 contains general provisions for the construction and testing of any electrical apparatus to be used in explosion hazar-dous areas. The EN 60079 standards listed below describe diffe-rent technical implementations of ignition protection classes: Pressure-tight encapsulation (EN 60079-1) Pressurized encapsulation (EN 60079-2) Powder-filled encapsulation (EN 60079-5) Oil immersion (EN 60079-6) Increased safety (EN 60079-7) Intrinsic safety (EN 60079-11) Ignition protection n (EN 60079-15) Moulded encapsulation (EN 60079-18) Intrinsically safe electrical systems (EN 60079-25) Optical radiation (EN 60079-28)

EN 60079-11 – Intrinsic safety (i)

All methods of protection attempt to contain an explosion on the inside of the housing and to prevent penetration of an ignitable gaseous mixture.

The method of “intrinsic safety“ is based on a different approach. It limits the electrical energy to such an extent, that elevated temper atures, sparks or arcs are incapable of generating the energy needed to ignite an explosive atmosphere.

Due to the limitation of electrical energy, these circuits are espe-cially suited to application in the field of measuring, control and instru mentation. The method of “intrinsic safety“ has some signi-ficant advantages over other protection methods, e.g. mainte-nance and wiring of live circuits. Thanks to the use of inexpensive components, these systems are easy to handle and cost effective, and several suppliers offer components with protection class „i“.

Definition of terms

Explosion

An explosion is an exothermic reaction of a material (such as gas, fumes, or dust) occurring at a high reaction speed. The risk of an explosion exists wherever there is the probability of an explosive atmosphere. An explosive atmosphere may occur wherever dusts, flammable gases or liquids are handled, processed, trans-ported or stored. Such hazardous atmospheres can be present for instance in chemical industries, gas stations, refineries, power plants, paint shops, vehicles, sewage plants, grain mills, airports, grain silos and filling plants.

Explosion hazards

Explosion hazards only exist in locations in which ignitable concentrations of flammable substances can

exist under normal operating conditions or in the event of faults, and when these conditions provide the probability that a dangerous substance to air mixture is enough to form an ex-plosive mixture;

where the explosive or ignitable mixtures can come in contact with a source of ignition and continue to burn after ignition.

Explosive mixture (general term)

A combustible (flammable) mixture is a mixture of gases or va-pours, or a mixture of gases and vapours with mists and dusts, ca-pable of propelling a reaction after ignition.

Explosive atmosphere

An explosive atmosphere contains gases, vapours, fumes or dusts mixed with air as well as the usual filler materials that can explo-de spontaneously under atmospheric conditions (see also ‘Explo-sive mixture’). An explosive atmosphere may occur wherever dusts, flam mable gases or vapours are handled, processed, trans-ported or stored.

Explosive atmosphere (hazardous)

A hazardous explosive atmosphere is a mixture containing con-centrations of flammable gases or vapors that, when ignited, can cause damage to persons directly or indirectly through an explosion.



Hazardous area

A hazardous area is an area in which there is a risk of explosion, i.e. a hazardous explosive atmosphere can occur due to local ope-rating conditions. Such hazardous atmospheres can be present for instance in chemical industries, gas stations, refineries, power plants, paint shops, vehicles, sewage plants, grain mills, airports, grain silos and filling plants.

Ignition triangle

In order to have an explosion, the following three components must be present simultaneously:

Possible sources of ignition hot surfaces flames and hot gases mechanically generated sparks electrical installations transient currents static electricity lightning, ultrasonic energy

Oxidizers air (21 % oxygen) pure oxygen oxygen releasing compounds (potassium permanganate)

Flammable substances flammable concentrations of gases and powders from liquids

or solids with ignition capability.

Explosive limits

A mixture is only explosive if the concentration is within certain material specific limits. These limits are called the upper and lo-wer explosion limits and are listed in appropriate tables.

Flash-point

The flash-point is the lowest temperature at which a liquid relea-ses sufficient vapors that can be ignited when close to an energy source and extinguished when the energy source is removed.

Primary and secondary explosion protection measures

Basically there are two methods used to prevent an explosion.

Primary explosion protection

The primary method of explosion protection comprises measures which prevent formation of a dangerous atmosphere: avoiding the use of flammable liquids increasing the flashpoint limiting the concentration to safe levels natural and technical ventilation Monitoring of the concentration…

(see also ‘Secondary explosion protection’)

Secondary explosion protection

The secondary method of explosion protection comprises mea-sures which prevent ignition of a dangerous atmosphere. Here, constructive or electrical techniques are used to segregate the electrical parts of the equipment likely to ignite a

dangerous mixture, by keeping the explosive atmosphere away from the ignition source

prevent an explosion by impeding the propagation to the sur-rounding explosive atmosphere

(see also ‘Primary explosion protection’)

Electrical equipment featuring ignition protection class „Intrinsic Safety“ (IEC/EN 60079-11)

Intrinsically safe and associated electrical equipment

The term “intrinsic safety“ implies that the electrical energy of an intrinsically safe circuit is limited to such an extent that a thermal effect or spark is incapable of igniting an explosive atmosphere under specified conditions.

TURCK devices for use in explosion hazardous areas comply with the ignition protection class “intrinsic safety“. The devices are di-vided into two different kinds of electrical equipment, intrinsi-cally safe equipment and associated equipment. The different de-vices types are differently labeled (see „Marking of devices“). Intrinsically safe electrical equipment incorporates only intrinsi-cally safe circuits. Direct installation in explosion hazardous areas is permitted, provided that all related requirements are met. An example is a NAMUR sensor approved according to EN 60947-5-6 or a transmitter.

Associated electrical equipment is any equipment which may in-corporate both intrinsically safe and non-intrinsically safe circuits. Intrinsically safe devices may be connected to associated electri-cal equipment, provided that all essential conditions for this kind of interconnected assembly are fulfilled. An isolating switching amplifier would be an associated electrical device and the con-nected NAMUR sensor is the intrinsically safe device.

Associated electrical equipment must generally be installed out-side the hazardous area. If installed within the hazardous area, addi tional protection measures must be provided. Many TURCK devices are approved for zone 2, allowing to install devices in the Ex-area. All TURCK devices featuring intrinsically safe circuits are classified as associated equipment, such as the interfacemodul for example.

Simple electrical equipment

Simple components and simple equipment that do not generate or store more than 1.5 V, 0.1 A and 25 mW, and do not require a test certificate are classified as “simple electrical equipment” (e.g. thermocouples). This equipment is defined in the standard EN 60079-14.


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Categories

Intrinsically safe and associated electrical equipment are divided into 3 categories according to 60079-11. This classification is determ ined by the failure probability and the ignition capability of the intrinsically safe circuitry.

Category ia:

Category „ia“ indicates that the electrical equipment should not be able to ignite a dangerous mixture during normal operation and in the event of a single fault, nor in the event of any combi-nation of two faults. Intrinsic safety must be maintained even when two inde pendent faults occur at the same time. Therefore, components of any equipment of category ”ia” that are suscepti-ble to faults must be present in triplicate.

Category ib:

An electrical apparatus, category „ib“ should not be capable of causing ignition under normal operating conditions in the event of a single fault. Intrinsic safety must be maintained in the event of a single fault. A fault could be the failure of a component that is suscept ible to disturbances. Any electrical equipment classified as ”ib” must have all components in duplicate

Category ic:

Electrical equipment classified as category ”ic” should not be ca-pable of causing ignition during normal operation. This ignition protec tion class replaces the ignition protection class „nL“ as from 2011 for installation in zone 2. The advantages of intrinsi-cally safe circuits are thus also available there.

Ignition protection class n (EN 60079-15)

Electrical equipment featuring ignition protection class n can only be installed in zone 2 or 22. It should neither cause ignition nor be serviced during normal operation. This should be guaran-teed through labels and mechanical locking.

Groups and temperature classes

Electrical equipment for use in explosion hazardous areas is clas-sified into groups and classes based on the likelihood of an ex-plosion danger. This is of great importance from a safety aspect as well as an economical aspect because it determines the requi-rements that must be met by the electrical equipment. The defi-nition of groups is based on the location in which the equipment is going to be used. Group I classified equipment may be used in mines susceptible

to firedamp and must conform to EN 60079 and additional mi-ning standards (e.g. EN 50303).

Group II classified equipment is used in all explosion hazardous areas except mining applications susceptible to firedamp.

Group II classified equipment is used in all explosion hazardous areas except mining applications susceptible to firedamp. De-pending on the application, different flammable materials with different ignition energy ratings are needed. From a practical point of view, subdividing Group II is therefore necessary and ma-kes sense, not only for economical reasons.

The subdivision of Group II equipment is based on the different ignition energy of the flammable materials. The different groups are classified by capital letters in ascending alphabetical order ac-cording to the hazard risk of the associated material. Materials belonging to group C require less ignition energy than Group A materials (see table 1)

T1 T2 T3 T4 T5 T6

I methane

II A acetone,ethane,ethyl acetate,ammonia,benzene,acetic acid,carbon monoxide,methanol,propane,toluene

ethyl alcohol, i-amyl acetate,n-butane,n-butyl alcohol,

benzines,diesel fuel,aviation fuels,fuel oils,n-hexane

acetaldehyde, ethyl aether

II B town gas(coal gas)

ethylene*)

II C hydrogen ethylene*) carbon disulfide*)

*) no authorized regulations available

Tab. 1: Flammable materials – groups and temperature classes

Temperature class

The temperature class specifies the maximum allowable surface temperature of an apparatus. In this category, the explosion pro-tected apparatus can be approved for different temperature clas-ses – a decision which depends on technical and economical considerations.

In the majority of cases, explosion proof equipment for the lo-west temperature can be very expensive to buy and install. By comparison, using products featuring ignition protection class „intrinsic safety“ is more efficient and cheaper. Only intrinsically safe equipment for direct installation in Ex areas requires tempe-rature classification. For associated apparatus this classification is not needed.



Ignition temperature

The ignition temperature (defined as the temperature at which a mixture self-ignites during testing) is directly related to the temper ature 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 pre-vent an ignition (see table 2).

Temperature class IEC/EN NEC 505-10

Maximum surface temperature of de-vice (°C)

Ignition temperatu-res of flammable materials (°C)

T1 450 >450

T2 300 >300 ≤ 450

280 >280 ≤ 300

260 > 260 ≤ 280

230 > 230 ≤ 260

215 > 215 ≤ 230

T3 200 > 200 ≤ 300

180 > 180 ≤ 200

165 > 165 ≤ 180

160 > 160 ≤ 165

T4 135 > 135 ≤ 200

120 > 120 ≤ 135

T5 100 > 100 ≤ 135

T6 85 > 85 ≤ 100

Tab. 2: Temperature classes with maximum admissible surface temperatures and ignition temperatures

Device groups and categories acc. to the ATEX directive

The ATEX directive prescribes a clear marking of the application and the constructional level of safety. EN 60079-11 also provides detailed information on how the protection measures were rea-lised and which applications are permitted and uses similar terms, but the information provided by EN 60079-11 and ATEX may be essentially different.

The first criterion of the ATEX directive is the device group. Like the groups described above, the different groups are defined and described according to their place of use.

Device Group I: For mining underground with a potential ha-zard due to firedamp and/or combustible dusts.

Device Group II: For all other locations in which a potentially explosive atmosphere exists.

The second criterion is the device category, defining the level of safety:

Device category 1: 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 safety.

Device category 2: 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 le-vel of safety.

Device category 3: Normal safety; the device ensures the requi-site level of safety during normal operation.

Devices classified as Group I (underground mining susceptible to firedamp) uses the prefix M, e. g. M1, in addition to the category clas sification.

The third criterion is the substance group which characterises the application of devices in particular atmospheres:

Substance group G: Explosion protection in explosive atmos-pheres due to gases, vapours or mists (G: gas)

Substance group D: Explosion protection in explosive atmos-pheres due to dusts (D: dust)

The equipment category also determines whether the device is an associated apparatus or an intrinsically safe apparatus. If it is an asso ciated apparatus the device category is put into round brackets, for example II (1) G.

Equipment protection level EPL

Devices are classified according to their potential hazard. Accor-ding to IEC 60079-0 equipment protection levels are defined as follows:

Gas explosion protection

EPL Ga: Device with very high protection level The device is no potential source of ignition and provides the

requisite level of safety when used for its intended purpose and with irregularly arising faults.

EPL Gb: Device with high protection level The device is no potential source of ignition and provides the


EPL Gc: Device with increased protection level The device is no potential source of ignition and provides the

requisite level of safety. The device features additional protection to ensure the requisi-

te level of safety.

Dust explosion protection

EPL Da Device with very high protection level The device is no potential source of ignition and provides the


EPL Db: Device with high protection level The device is no potential source of ignition and provides the


EPL Dc: Device with increased protection level The device is no potential source of ignition and provides the

requisite level of safety. The device features additional protection, to ensure therequisi-

te level of safety with faults expected to occur regularly.

EPL and zones

Devices with a higher protection rating can be use in applications with lower protection ratings. Devices approved for zone 0 can also be applied in zone 1 and devices for zone 20 in zone 21.


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Device protection rating Zone

Ga 0

Gb 1

Gc 2

Da 20

Db 21

Dc 22

Zone classification

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:Classification Zones 0, 1 and 2 for gases, vapour and mist Zones 20, 21 and 22 for dusts

Zone classification for gases

Zone 0

Zone 0 comprises locations in which a dangerous explosive at-mosphere is present continuously or frequently. The definition is extended by the term „frequently“. The example shows a gas sta-tion with zones classified as 0.

Intrinsically safe devices designed for use in zone 0 must meet ca-tegory ”ia” safety standards and must have no live contacts. Gal-vanic isolation between intrinsically safe and non-safe devices is to be preferred. If grounding of the intrinsically safe circuit is re-quired for functionality, this must be done outside zone 0, but as close as possible to zone 0. The devices must as well be approved for gas groups IIA, IIB and IIC.

Zone 1

Zone 1 are locations in which explosive atmospheres are likely to occur. Here ATEX does not incorporate any changes. The examp-le shows the area near the gas pump during refuelling classified as zone 1.

Generally the following areas in industrial plants are considered to be zone 1 locations: in the vicinity of zone 0 close to inspection openings

near filling and draining devices inside of machinery

Any device certified for zone 1 must be group IIA, IIB or IIC and at least category ”ib”.

Zone 2

Zone 2 are locations in which an explosive or dangerous explosi-ve atmosphere is likely to occur only rarely and if, only for a short time. According to the ATEX definition, an explosive atmosphere should not occur, but, if it does, only infrequently and for a short period. The following industrial areas comply with it: Areas near zone 0 and 1 Areas near flange seals whenever standard flange joints are

used Areas near pipes in closed rooms

Unlike apparatus for zones 0 and 1, devices for use in zone 2 do not require a test certificate by an authorized body. Devices must conform to category 3 and must meet the following criteria (EN 60079-15): restricted breathing enclosures (excess temperature 10 k only) sealed enclosures (various test methods/requirements) simple pressurized enclosure(like „p“ without purging) limited energy(intrinsic safety without safety factor, category) encapsulated switching devices (simple pressurized enclosure) lower requirements for devices in zone 1, e.g.

- clearances and creepage - housing impact test - plastic materials - construction of lamp holders and starters

Installation of devices in zones 0 to 2

For installation in zones 0 to 2 (gas, vapour) it is required that in-trinsically safe and associated devices must meet at least those require ments applying to the zone in which the intrinsically safe apparatus is to be installed. If a device meets higher require-ments, operation is obviously permitted. The national regulations apply to interconnected assembly and installation of devices. Ple-ase refer to „Guidelines for use of devices with intrinsically safe circuits“ below.



Combustible dusts and fibers

Zone 20

According to ATEX, zone 20 is classified as an area in which a dan-gerous explosive atmosphere in the form of a dust cloud is continu ously present, or occurs frequently, or for a long period. The possibility of a dust deposit with a known or excessive thick-ness is given. The presence of dust deposits as a single event does not constitute a zone 20 classification. Usually, these condi-tions can only prevail inside an enclosure, pipes and instruments.

Areas, in which dust deposits occur, but where clouds of dust are not present constantly, frequently or for a long term, do not be-long to this zone.

Zones 21 and 22

Zone 21

Areas in which a potentially explosive atmosphere in the form of a dust cloud can occur occasionally during normal operation. Dust deposits or layers of combustible dust will usually be present.

These can be areas in the close vicinity of filling or dust extraction stations, where dust deposits are present and explosive concentra tions of flammable dust mixed with air may occur du-ring normal operation.

Zone 22

Areas in which it is unlikely that a potentially explosive atmos-phere in the form of a dust cloud occurs during normal operati-

on. If such an atmosphere occurs, then only for a short period, or in the event of dust accumulation, or in layers of combustible dust.

For example, areas in the vicinity of equipment containing dust which can escape through leakages and where dust deposits can build up (e.g. mills from which dust is released and accumulates).

Installation of devices in zone 20 to 22

Regarding areas of combustible dust, installation, operation and maintenance of devices are subject to the national regulations (EN 60079-14/EN 61241-14). Intrinsically safe devices mounted in zone 20 to 22 must have the appropriate approval. Associated equip ment does not require an approval for flammable dusts, an approval for gases and vapour is sufficient. It must be ensured that the limit values of intrinsic safety of the EC type examination certificate are met in the case of an interconnected assembly. Then it is permitted to mark the intrinsically safe device as II 1 D and the associated equipment as II (1) G. To avoid mistakes, the marking II (1) G, II (1) D is usual.

During installation the special conditions of dust protection must be observed. Simple devices for use in zones 20 to 22 must have an approval, whereas this is not necessary for simple devices ap-plied in zones 0 to 2.

Marking of devices

Marking of devices conforming to CENELEC

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 60079-0/...-11 must provide the following information: manufacturer’s name or trademark part number serial number authorized body Ex symbol ignition category, e.g. „ia“ ”x” after the test certificate number indicates that special con-

Zone classification

Likelihood of an explosive atmosphere

Compliance with safety requirements by

Requirements fulfilled by:

Equipment group

Related equipment category

Additional equipment category

Zone 0 (gas, …) Zone 20 (dust)

Continuously, for long periods or frequently

2 independent means of protection

II 1G (for gas, ...) –

III 1D (for dust)

Zone 1 Zone 21

Occasionally 1 independent means of protection

II 2 G 1

III 2 D

Zone 2 Zone 22

Unlikely or infrequently - for a short period only

Normal operation II 3 G 1 or 2

III 3 DTab.3: Zone classification – equipment categories


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ditions must be met (see certificate for special conditions) designated group together with the respective subdivision

(e.g. IIC) temperature class or maximum surface temperature (for group

II devices) test authority, date and file number device protection rating, e.g. „Ga“

An intrinsically safe device is to be marked as follows:

Ex ia IIC T6 Ga

Ex complies with European standard

ia Ignition protection (category)

IIC explosion category

T6 temperature class

Ga device protection rating

Associated equipment is to be marked as follows:

[Ex ia Ga] IIC

Ex complies with European standard

Ia Ignition protection (category)

IIC explosion category

Ga device protection rating

Marking of devices conforming to ATEXThe test certificate number of the EC type examination certificate acc. to the ATEX directive:

PTB 97 ATEX 2128X

PTB authorized body

97 year of examination

ATEX acc. to directive 94/9/EG

2128 test certificate number

X special conditions

Within the European Union the devices must meet the respective requirements. If the manufacturer fulfills these, he is permitted to affix the CE sign with the identification number of the notified body, which carried out the quality assurance system approval.

0102

The test authority TÜV Hannover has the ID number 0044, EXAM (BVS) Bochum 0158 and PTB Braunschweig 0102.

The year of production and the constructional level of safety acc. to ATEX must be also contained in the device’s marking.For intrinsically safe devices the marking would be:

II 1 G

II all areas except mining

1 very high safety level suited for zone 0

G explosion protected against gas, vapour and mist

Associated equipment is identifiable by round brackets enclosing the device category:

II (1) G

II all areas except mining

(1) may not be installed in Ex areas

G explosion protected against gas, vapour and mist

Manufacturer obligations

The manufacturer must provide a certificate of conformity and EC type examination certificate from an authorized test body.

The authorized body implements tests and certifies that the de-vices comply with the regulations and standards of the explosion hazardous area. The manufacturer is required to supply a type test sample to an authorized test body, which draws up a test re-port to be submitted to the notified body entitled to issue the EC type examination certificate after verifying conformity. Notified bodies and external inspection bodies are registered centrally.

The EC type examination certificate contains all Ex-relevant data for devices of zone 0 and 1. It is the manufacturer‘s responsibility to keep a copy of the certificate. Along with the certificate, the manufacturer provides an instruction manual with all relevant Ex data. In addition, the manufacturer issues a declaration of confor-mity, stating that all applicable standards and directives are met. The user needs these documents to document compliance of the system installation.

CE marking of equipment

Devices for use in explosion hazardous areas are provided with the CE marking and the identification code of the testing authori-ty. The assessment procedure for CE marking is clearly defined and depends on the device category. The example shown relates to device category 1, featuring the highest safety level. The appli-cable annexes of the directive 94/9/EC are also shown.

Different annexes apply to the various device categories.



QA – Assessment of the quality assurance system

The manufacturer of intrinsically safe devices, categories 1 and 2, must have an approved quality management system. This appro-val is needed to ensure that the manufacturer produces the de-vices according to the test type sample and that conformity to re-levant protection regulations is given. Assessment of the quality assurance system is carried out by a notified body. Assessment can be achieved in two different ways:Assessment and certification can be done directly within the scope of certification according to ISO 9000ff. Approval of those fields associated with explosion protection is accomplished in co-operation with an expert of the notified body. If the ISO certifica-te has already been granted, it is possible to certify those parts re-lating to explosion protection subsequently within the scope of an additional audit. The following illustration shows both possibilities:

TURCK’s manufacturing sites for explosion protected devices are certified according to ISO 9001 and have a quality system approval.

Guidelines for use of devices with intrinsically safe circuits

Guidelines for use of devices with intrinsically safe circuits

The national regulations and standards are the basis for use of devices with intrinsically safe circuits. These must be strictly ob-served and followed. The user is obliged to inform himself of all revisions. The following guidelines relate to the ATEX (94/9/EC) directive of the member states of the European Union, especially to the field of explosion protection in areas exposed to hazards by gas. If the device is classified as associated equipment with in-trinsically safe and non-intrinsically safe circuits, it may not be ins-talled in explosion hazardous areas It is only permitted to con-nect intrinsically safe devices located in the hazardous area to the intrinsically safe circuits of this device. The intrinsically safe con-nections of TURCK devices carry a blue marking.

When interconnecting devices within such an assembly it is man-datory to provide a proof of intrinsic safety (EN 60079-14: 2004, chap. 12.2.5). This is required to verify that all data related to ex-plosion protection of the devices allow joint operation. Verifica-tion must include the internal capacitances and inductances of the cables used. Please refer to the special section „ Proof of in-trinsic safety“ for more information.

Intrinsically safe circuits should never be interconnected with non-safe circuits. Even if only interconnected once, it is possible that essential protective elements are damaged without the user being aware of this fact. A simple function test is not suited to ve-rify a damage of this kind. Once intrinsically safe circuits have been connected to the non-intrinsically safe circuit, it is not per-mitted to use the device subsequently as intrinsically safe equip-ment. The governing regulations cover installation of intrinsically safe circuits, mounting to external connections, cable characteris-tics and cable installation. Cables and terminals with intrinsically safe circuits must be marked and separated from non-intrinsically safe circuits or feature appropriate isolation (> 1.500 VAC). The following is an excerpt from the requirements according to EN 60079-14: Protection against external electrical or magnetic fields (e.g.

power lines) Prevent conductor splicing of fine wires through wire sleeves Minimum cross section of 0.1 mm (also single wires of a con-

ductor): 0.1 mm Protection against damage (mechanical, chemical, thermic …) Armouring, metal cladding, shielding of cables and lines Common use of single-core non-sheathed cables of intrinsi-

cally and non-safe circuits in one line is not permitted Separate error assessment when using multi-conductor cables

and lines If cables have to be color-marked, use light-blue.

When mounting IMB devices (interface module backplane), further instructions must be observed, owing to their open const-ruction and special connection technology: The devices have to be mounted such as to comply at least

with protection class IP20 acc. to IEC publication 60529. Gene-rally, this is achieved by plugging dummy modules (IMB-BM) in the free slots.

Connections for intrinsically safe and non-intrinsically safe cir-cuits must either be separated by a physical barrier so that they are at least 50 mm (thread measure) apart from each other, or each connection must be provided with cable sleeves which cannot slip off and ensure covering of all bare parts. A thread measure is defined as the distance between circuits separated by a physical barrier. The reason for this regulation is that it is possible to work with live intrinsically safe circuits; thus it must be avoided that these come into contact accidentally with any non-safe connection components. This distance is only requi-red for external connections which can be accessed by the user. The minimum distance between two intrinsically safe cir-cuits must be 6 mm and separation from other (grou nded) me-tal parts must be 3 mm.


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IMB devices must be coded as a protection measure against mismatching. This is done by inserting coding keys in the ap-propriate bores; the matching openings are located in the cor-responding retainers.

The approval expires, if the device is repaired, altered or opened by a person other than the manufacturer or an expert unless the device-specific instruction manual explicitly permits such inter-ventions. Only an expert is familiar with the information on pro-tection measures needed to assure that the device is still in ac-cordance with the applicable regulations after such an intervention. Visible damages to the device’s housing (e. g. black or brown discoloration due to heat accumulation, perforation or deformation) indicate a serious error and the device must be tur-ned off immediately. The associated equipment must also be checked.

Inspection of a device with regard to all relevant aspects of explo-sion protection may only be carried out by an expert or the manufac turer. The operation of the devices is only permitted in conjunction with the permitted data. The supply voltage for ex-ample should never exceed or fall below the indicated maximum value or the temperature range during operation.

Intrinsically safe circuits with galvanic isolation - as is the case with TURCK devices - should not be grounded, unless not absolu-tely necessary from a functional point of view. Circuits without galvanic isolation, like provided by Zener barriers, always require grounding. EN 60079-14 includes the relevant grounding regula-tions. Within zone 0 grounding of a circuit is not necessary. If grounding is neces sary for functional reasons, then it must be carried out in close vicinity of zone 0.

Prior to every initial set-up or after any change of the device in-terconnection within the assembly, it must be ensured that all applicable regulations, directives and framework directives are met, that all safety regulations are fulfilled and that the device is functioning prop erly. Only then the operation is permitted.

Mounting and connection of the device should only be carried out by qualified and trained staff familiar with the relevant natio-nal and international regulations of explosion protection to ensu-re correct operation.

The system operator must ensure that the system is always in the required safe condition. The system must be inspected conti-nuously and necessary maintenance work must be carried out immediately while observing the safety regulations. The system must be tested in case of need, latest every three years.

Proof of intrinsic safety

Proof of intrinsic safety

According to EN 60079-14 a proof of intrinsic safety must be pro-vided to confirm that equipment interconnected within an as-sembly meets the requirements of intrinsic safety. In this context, a clear distinction is made between two different types of circuits: Simple intrinsically safe circuit with a single associated device

and at least one intrinsically safe device without additional supply.

More than one associated devices capable of supplying electri-cal energy to the intrinsically safe circuit, not only during nor-mal opera tion but also in a fault condition.

Intrinsically safe equipment: No. Designation Type

Manufacturer Test certificate no. Expl. group Ui

[V]Ii

[mA]Pi

[mW]Li

[µH]Ci

[nF]

1 Proximity switch BIM-INT-Y1X TURCK KEMA 01 ATEX 1264 X EEx ia IIC T6 20.0 60.0 80.0 150.0 150.0

2 Proximity switch BI1-EG05-Y1 TURCK KEMA 02 ATEX 1090 X Ex ia IIC T6 20.0 60.0 130.0 150.0 150.0

⇒ Cable inductances and capacitances: (Manufactures spec. or LC = 1 mH/km. CC = 110 nF/km)

Total cable length: 130 m 0.13 14.3

Total inductances and capacitances: (ΣLi and ΣCi) 150.13 164.3

Intrinsic safety is achieved if all conditions are fulfilled: U0 ≤ Ui I0 ≤ Ii P0 ≤ Pi L0 ≥ ΣLi C0 ≥ ΣCi

Associated equipment: Designation Type

Manufacturer Test certificate no. Expl. group U0

[V]I0

[mA]P0

[mW]L0

[µH]C0

[nF]

Isolating switching amplifier

IMB-DI-451EX-P/24VDC TURCK TÜV 08 ATEX 554880 [Ex ia Ga] IIC 12.0 12.4 37.2 10.0 0.49

Example: Proof of intrinsic safety



Simple circuit

The first definition of a simple intrinsically safe circuit requires the observance of all electrical limit values stated in the EC type exa-mination certificate and the power characteristics. If these condi-tions are met, the user is entitled to keep a proof of intrinsic safe-ty. Inductances and capacitances of the installed cables must be taken into account. The intrinsic safety of a simple circuit is veri-fied, if the limit values are maintained according to the following conditions:

Associated equipment

Conditions Intrinsically safe de-vice + cable

U0 ≤ UI

I0 ≤ II

P0 ≤ PI

L0 ≥ LI+LC

C0 ≥ CI+CC

Circuits with non-linear output characteristic of associated equipment and

(at the same time) the presence of distributed reactances only.

If massed reactances are present and under the condition of line-ar limitation by the associated equipment it must be checked if: C0 > 1 % of CI

L0 >1 % of LI

If one of the two conditions apply, the percentage of C0 and L0 must be reduced by half (50% rule).

The cable characteristics provided by the manufacturer should be used. Should these not be available, the following typical values (acc. to EN 60017-14, Teil 12.2.2.2.) are recommended: 200 pF/m und 1 mH/m oder 30 μH/Ω.

If the value P0 of the associated equipment is not specified, a line-ar characteristic must be available, on the basis of which P0 can be calculated: P0 = ¼ × I0 × U0

The connection of proximity switches to isolating switching amp-lifiers, or 2-wire transmitters to isolating transducers, or solenoid valves to a valve control module can be considered as simple cir-cuits. The limit value indexes of the certificate of conformity and the EC type examination certificate differ. In this overview the in-dexes according to EN 60079-14 are used. Index „0“ stands for maximum output values and „I“ for maximum input values.

The proof of intrinsic safety should be laid down in a standar-dized document to facilitate clear documentation. The document should contain the date, the name of the manufacturer, the cir-cuit type and the type code.

Interconnection of several devices

The second case considers interconnection of several active asso-ciated devices. Here it is not permitted to apply the electric limit values of the EC type examination certificate for the proof of in-trinsic safety. This case differs fundamentally from the first one.

Different limit values apply to an assembly of individually associa-ted devices. Such an assembly will always be classified as equip-

ment according to category „ib“, even if the single devices com-ply with to category „ia“. An assembly may therefore not be installed in zone 0.

A detailed description of interconnection and assembly is bey-ond the scope of this introduction. The related calculation me-thods and an example are contained in annexes A and B of EN 60079-14. Additionally, the ignition curves of IEC 60079-11 are needed. EN 60079-11 also contains the ignition curves.

When interconnecting associated devices whose typical curves are not entirely linear, a special procedure must be applied. This procedure is explained precisely in EN 60079-25.

Applicability of approvals

Applicability of approvals / national approvals

Equipment certified according to the ATEX directive may be placed on the market, installed and put into service within the member states of the European Union.

Even though Switzerland does not belong to the EU, approvals according to ATEX are accepted. An approval by SEV is not requi-red, if the customer provides the mandatory documentation, i.e. the instruction manual, the EC type examination certificate, the CE declara tion and the certificate of the quality management au-dit relating to explosion protection.

Many states outside the European Union explicitly request their own national approval. Therefore TURCK devices feature appro-vals for many different countries. National approvals are required in countries such as the USA, Canada, China, Japan, Australia, CIS states, whereas other states accept approvals issued by other sta-tes. For this reason it is indispensable to be familiar with the nati-onal require ments.

In many states approvals are granted for a certain period only. Therefore it is recommended that check is made whether the ap-proval has expired or has been prolonged accordingly. If an ap-proval expires after installation, many countries accept further operation.

Approvals according to ATEX and approvals in the USA and Cana-da are not subject to a time limit.

Approvals available on the internet

Overview of approvals

TURCK offers their customers the opportunity to view all valid ap-provals and to download these at Turck website.


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