ExTR Reference No. NO/NEM/ExTR12.0013/00FILE/IECEX_TR12.0013_60079_11.pdf · ExTR Reference No. NO/NEM/ExTR12.0013/00 TRF No. ExTR60079-11_5B-1 Page 2 of 13 IEC 60079-11 Clause Requirement

ExTR Reference No. NO/NEM/ExTR12.0013/00

Page 1 of 13

ExTR Reference Number .............. : NO/NEM/ExTR12.0013/00

ExTR Free Reference Number ...... : 218314

Compiled by + signature (ExTL) .... : Stig André Norheim

Reviewed by + signature (ExTL) .... : Arne Hortman

Date of issue ................................. : 2012-08-30

Ex Testing Laboratory (ExTL) ........ :

Address ........................................ : P.O. Box 73 Blindern, N-0314 Oslo, Norway

Applicant’s name ........................... : Kongsberg Maritime AS

Address ........................................ : Haakon VIIs gt. 4 N-7005 Trondheim, Norway

Standard ....................................... : IEC 60079-11:2006, 5th Edition

Test procedure .............................. : IECEx System

Test Report Form Number ............. : ExTR60079-11_5B-1 (released 2010-08)

Instructions for Intended Use of Ex Test Report: An Ex Test Report provides a clause-by-clause documentation of the initial evaluation and testing that verified compliance of an item or product with an IEC Ex standard. This Ex Test Report is part of an ExTR package that may include other Ex Test Report, Addendum and National Differences documents, along with a single ExTR Cover. An Ex Test Report is to be compiled and reviewed by the ExTL. The Issuing ExCB indicates final approval of the Ex Test Report as part of the overall ExTR package on the associated ExTR Cover.

Copyright © 2010 International Electrotechnical Commission System for Certification to Standards Relating to Equipment for use in Explosive Atmospheres (IECEx System), Geneva, Switzerland. All rights reserved. This blank publication may be reproduced in whole or in part for non-commercial purposes as long as the IECEx System is acknowledged as copyright owner and source of the material. The IECEx system takes no responsibility for, and will not assume liability for, damages resulting from the reader's interpretation of the reproduced material due to its placement and context.

Possible test case verdicts:

- test case does not apply to the test item .................... :N / A

- test item does meet the requirement ......................... :Pass

General remarks: The test results presented in this Ex Test Report relate only to the item or product tested.

"(see Attachment #)" refers to additional information appended to this document. "(see appended table)" refers to a table appended to this document. Throughout this document, a point is used as the decimal separator.

The technical content of this Ex Test Report shall not be reproduced except in full without the written approval of the Issuing ExCB and ExTL.

IECEx TEST REPORT IEC 60079-11

Explosive atmospheres – Part 11:

Equipment protection by intrinsic safety "i"


TRF No. ExTR60079-11_5B-1 Page 2 of 13

IEC 60079-11

Clause Requirement – Test Result – Remark Verdict

1 SCOPE

2 NORMATIVE REFERENCES

3 DEFINITIONS

4 GROUPING AND CLASSIFICATION Pass

5 LEVELS OF PROTECTION AND IGNITION COMPLIANCE

5.1 General Refer to Appendix A.1 for details. Pass

5.2, 5.3, 5.4

Level of protection Level of protection is “ia”

One fault, two faults and numerous non-countable faults have been applied for the testing and assessment.

Refer to Appendix A.1 for details.

Pass

5.5 Spark ignition compliance Refer to Appendix A.2 for details. Pass

5.6 Thermal ignition compliance

5.6.1 General Refer to Appendix A.3 for details. Pass

5.6.2 Temperature for small components

Refer to Appendix A.3.1 for details. Pass

5.6.3 Wiring within apparatus No wiring within the apparatus. N/A

5.6.4 Tracks on printed circuit boards Refer to Appendix A.3.3 for details. Pass

5.7 Simple apparatus Not a simple apparatus. N/A

6 APPARATUS CONSTRUCTION

6.1 Enclosures Ref. below. Pass

6.1.1 Apparatus complying with Table 5 The electronic unit board GCB-120 is coated and mounted in the enclosure of stainless steel (AISI 316) of main product GC-120/-U which is protected against ingress of dust and water. Cover sealed with O-ring. Degree of protection was not tested.

Pass

6.1.2 Apparatus complying with Annex F N/A



IEC 60079-11


6.2 Facilities for connection of external circuits

Ref. below. N/A

6.2.1 Terminals The connection facilities for connection of temperature element have a clearance between intrinsically safe circuits according to table 5 and exceeds 2mm.

Pass

6.2.2 Plugs and sockets No plugs and sockets. N/A

6.2.3 Determination of maximum external inductance to resistance ratio (Lo/Ro) for resistance limited power source

Not a power supply apparatus. N/A

6.2.4 Permanently connected cable Are not used. N/A

6.3 Separation distances Ref. below. Pass

6.3.1 Separation of conductive parts The intrinsic safety of the equipment depends on safe separation distances.

Pass

6.3.1.1 Distances according to Table 5 Column 6 in table 5 has been evaluated for safety distances.

Pass

6.3.1.2 Distances according to Annex F Not used. N/A

6.3.2 Voltage between conductive parts Uo=28V from a barrier. Pass

6.3.3 Clearance The clearances is at least 2mm See description of each construction in the Appendix.

Pass

6.3.4 Separation distances through casting compound

Are not used. N/A

6.3.5 Separation distances through solid insulation

Are not used. N/A

6.3.6 Composite separations Not used. N/A

6.3.7 Creepage distance Safety components are measured with a creepage distances at least 2,0mm. Described in Appendix A.5

Pass

6.3.8 Distance under coating The creepage distances between each intrinsically safe circuit under coating are 1,2mm. And they are in accordance with table 5.

Pass

6.3.9 Requirements for assembled printed circuit boards

The circuit board is coated with conformal coating in two layers. Coating type is DOW CORNING 1-2577.

Pass

6.3.10 Separation by earth screens Not used. N/A

6.3.11 Internal wiring The safety of the devices does not depend on the insulation of internal wiring.

Pass

6.3.12 Dielectric strength requirement Voltage test with 500V AC 50Hz was performed between the circuits and the frame.

Pass

6.3.13 Relays Not used. N/A

6.4 Protection Against Polarity Reversal

The safety aspect doesn’t depend on having correct polarity.

N/A

6.5 Earth conductors, connections and terminals

No earth conductors. N/A



IEC 60079-11


6.6 Encapsulation N/A

7 COMPONENTS ON WHICH INTRINSIC SAFETY DEPENDS

7.1 Rating of components The safety components are rated with at least a safety factor of 1,5. The safety components and the rating is described in the Appendix A.4

The safety components are current limiting resistors.

Pass

7.2 Connectors for internal connections, plug-in cards and components

No such connectors or connections in the apparatus.

N/A

7.3 Fuses Not used.

N/A

7.4 Primary and secondary cells and batteries

Not used. N/A

7.4.1 General N/A

7.4.2 Electrolyte leakage and ventilation N/A

7.4.3 Cell voltages N/A

7.4.4 Internal resistance of cell or battery

N/A

7.4.5 Batteries in apparatus protected by other means of protection

N/A

7.4.6 Batteries used and replaced in explosive gas atmospheres

N/A

7.4.7 Batteries used but not replaced in explosive gas atmospheres

N/A

7.4.8 External contacts for charging batteries

N/A

7.4.9 Battery construction N/A

7.5 Semiconductors N/A

7.5.1 Transient effects Fed from a certified zener barrier. N/A

7.5.2 Shunt voltage limiters Not used. N/A

7.5.3 Series current limiters Not used. N/A

7.6 Failure of components, connections and separations

N/A

7.7 Piezo-electric Not used. N/A



IEC 60079-11


7.8 Electrochemical cells for the detection of gases

Not used. N/A

8 INFALLIBLE COMPONENTS, INFALLIBLE ASSEMBLIES OF COMPONENTS AND INFALLIBLE CONNECTIONS ON WHICH INTRINSIC SAFETY DEPENDS

8.1 Mains transformers Not used. N/A

8.1.1 Protective measures N/A

8.1.2 Transformer construction N/A

8.1.3 Transformer type tests N/A

8.1.4 Routine test of mains transformers N/A

8.2 Transformers other than mains transformers

Not used. N/A

8.3 Infallible windings N/A

8.3.1 Damping windings N/A

8.3.2 Inductors made by insulated conductors

N/A

8.4 Current-limiting resistors See Appendix A.4 for details.

The equipment contains current limiting resistors that are described. The loading of each component is described in the mentioned appendix above.

Pass

8.5 Blocking capacitors Not used. N/A

8.6 Shunt safety assemblies Not used. N/A

8.6.1 General Not used. N/A

8.6.2 Safety shunts Not used. N/A

8.6.3 Shunt voltage limiters Not used. N/A

8.7 Wiring, printed circuit board tracks, and connections

Safety shunts not used. N/A

8.8 Galvanically separating components

Are not used. N/A

8.8.1 General N/A

8.8.2 Isolating components between intrinsically safe and non-intrinsically safe circuits

N/A

8.8.3 Isolating components between separate intrinsically safe circuits

N/A



IEC 60079-11


9 DIODE SAFETY BARRIERS N/A

9.1 General This is not a single diode safety barrier. N/A

9.2 Construction N/A

9.2.1 Mounting N/A

9.2.2 Facilities for connection to earth N/A

9.2.3 Protection of components N/A

10 TYPE VERIFICATIONS AND TYPE TESTS Pass

10.1 Spark ignition test The principles of the assessments were used and the reference curves were partly used for the assessment.

Pass

10.1.1 General The board was tested for establishing the internal capacitance as seen from the terminals. The test is described in the Appendix A.2 for details.

Pass

10.1.2 Spark test apparatus The standard apparatus was used. Pass

10.1.3, 10.1.3.1, 10.1.3.2

Test gas mixtures and spark test apparatus calibration current

The voltage or current was increased to achieve the safety factor of 1,5 and the tests have been carried out according to EN 60079-11 with 21% Hydrogen in air

The 95mH 30mA, 24V was used.

Pass

10.1.4, 10.1.4.1, 10.1.4.2

Tests with the spark test apparatus – circuit test, safety factors

The safety factors were 1,5 for the tests. Pass

10.1.5 Testing considerations

10.1.5.1 General Pass

10.1.5.2 Circuits with both inductance and capacitance

None. N/A

10.1.5.3 Circuits using shunt short-circuit (crowbar) protection

N/A

10.1.5.4 Results of spark test The circuit did not ignite the gas mixture for the final test.

Pass

10.2 Temperature tests The temperature assessment was based on measurements. Ref. Appendix B Tests.

Pass

10.3 Dielectric strength tests Test performed between the intrinsically safe electrical circuit and frame. Test complies with clause 6.3.12 in IEC 60079-11.

Pass

10.4 Determination of parameters of loosely specified components

The components are well defined. N/A



IEC 60079-11


10.5 Tests for cells and batteries Not used. N/A

10.5.1 General N/A

10.5.2 Electrolyte leakage test for cells and batteries

N/A

10.5.3 Spark ignition and surface temperature of cells and batteries

N/A

10.5.4 Battery container pressure tests N/A

10.6 Mechanical tests N/A

10.6.1 Casting compound Not used. N/A

10.6.2 Sealing of components before encapsulation

Not used. N/A

10.6.3 Partitions Not used. N/A

10.7 Tests for apparatus containing piezoelectric devices

Not used. N/A

10.8 Type tests for diode safety barriers and safety shunts

Are not used (not applicable to transient effects).

N/A

10.9 Cable pull test Not used. N/A

10.10 Transformer tests Not used. N/A

11 ROUTINE VERIFICATIONS AND TESTS

11.1 Routine tests for diode safety barriers

Not used. N/A

11.1.1 Completed barriers N/A

11.1.2 Diodes for 2-diode “ia” barriers N/A

11.2 Routine tests for infallible transformers

Not used. N/A

12 MARKING

12.1 General Complies with the requirements. This Intrinsically safe apparatus apparatus is marked according to requirements specified in IEC 60079-0: 2007

Pass

12.2 Marking of connection facilities Ref. APPENDIX A: Description of product. Pass

12.3 Warning markings None. N/A

12.4 Examples of marking



IEC 60079-11


13 DOCUMENTATION The documentation includes the instructions required by Clause 30 of IEC 60079-0, and includes marking information as applicable after clause 12 above.

Pass

ANNEX A ASSESSMENT OF INTRINSICALLY SAFE CIRCUITS (NORMATIVE) Pass

ANNEX B SPARK TEST APPARATUS FOR INTRINSICALLY SAFE CIRCUITS (NORMATIVE)

Pass

ANNEX C MEASUREMENT OF CREEPAGE DISTANCE, CLEARANCES AND SEPARATION DISTANCES THROUGH CASTING COMPOUND AND THROUGH SOLID INSULATION (INFORMATIVE)

ANNEX D ENCAPSULATION (INFORMATIVE)

ANNEX E ENCAPSULATION (INFORMATIVE)

ANNEX F ALTERNATIVE SEPARATION DISTANCES FOR ASSEMBLED PRINTED CIRCUIT BOARDS AND SEPARATION OF COMPONENTS (NORMATIVE)

F.1 General N/A

F.2 Control of pollution access N/A

F.3 Distances for printed circuit boards and separation of components

N/A

F.3.1 Level of protection “ia” and “ib” N/A

F.3.2 Level of protection “ic” N/A



Measurement Section, including Additional Narrative Remarks

APPENDIX A: Description of product A.1 General overview The apparatus GC-120/ -U is a triple temperature transmitter with 4-10mA outputs. The transmitters are completely separated and each transmitter circuit shall be connected to a certified diode safety barrier with the appropriate safety parameters. The transmitter enclosure is made of stainless steel AISI 316. The safety aspects for GC-120/ -U affect serial current limiting resistors R32A-C, R33A-C og R1, R2, R5, R6 and R19. These components are judged to be the safety components. Safety Data Maximum input voltage Ui: 28V Maximum input current Ii: 147mA Maximum input power Pi: 0,9W Maximum internal capacitance Ci: 33nF Maximum internal inductance Li: 5µH The stated input values Ui, Ii, Pi are to be regarded as separate maximum values. It is a precondition that the supply barrier has a linear resistive output characteristic. The output terminals 3,4,5,6 are for the connection of sensing elements. The elements are not parts of the certified apparatus and may be used as “Simple apparatus” according to IEC 60079-11 clause 5.7. The cable connecting the sensing elements may be up to 300m. The capacitance and inductance of the cable need not be considered. Product picture of the GC-120/ -U

Type designation: GC-120/ -U The symbol “/ -U“ is the version of the variants which cover the temperature sensors Pt1000:



Control sketch:



A.2 Spark ignition consideration A.2.1 Resistive spark ignition The intrinsically safe apparatus GC-120 shall be connected to certified barrier with the following max. parameters described in the safety control drawing in the certificate. Maximum input voltage Ui: 28V maximum input current Ii: 147mA and maximum input power Pi: 0,9W Note that Maximum permitted short-circuit current according to table A.1 for 28V is 120mA and for permitted short-circuit current at 147mA is the voltage 25,5V A.2.2 Inductive spark ignition Inductance in the circuit: The circuit contains 2 EMI filter as is measured to 2,5µH each. Maximum allowed inductance in the circuit and with 147mA is 1,5mH. Li: 5µH A.2.3 Capacitive spark ignition Capacitors in the circuit: The sum of all capacitances is 67nF. Max permissible capacitance at 28V and 1.5X safety factor is 82nF. The internal capacitances are in series with the infallible resistors R32A-C (65Ω). The circuit was tested in the spark test apparatus: The capacitance 67nF serial connected with 65Ω was connected to an additional external capacitor of 50nF and charged to 28V x 1.5 = 42V. The 21% hydrogen mixture was not ignited during the 2,5 minutes(+) +2,5 minutes(-) test. The test was also performed with 60nF, but ignition occurred after 2 minutes. The Ci of the circuit was found to be equivalent to 33nF (≈82nF-50nF) A.2.4 Combination of inductive and capacitive spark ignition Not applicable A.2.5 Shunt short-circuit (crowbar) spark ignition Not applicable A.2.6 Other spark ignition considerations Not applicable A.3 Thermal ignition consideration A.3.1 Temperature for small components Resistor R32A-C and R33A-C are of type SMD 1206 (Rth=210K/W) and they have a surface area less than 20mm

2. Maximum power dissipation is 0,9W and the ambient is +70°C. Assessment for T4

classification according to component size ≤ 20mm2 and surface temperature ≤ 275°C.

Temp. assessment on SOT23 package. 1: Ui:28V and Pi:0,9W 2: Ii:147mA and Pi:0,9W



1) 28V and 0,9W => Gives a Short circuit current of 129mA. Max allowed current is 120mA . That gives a max power of 0,84W. =>R = 233,3Ω , P = 282/(233,3+130) * ¼ = 0,54W.

2) Power in V8 SOT-23 : Max power when Ri in V8 = Rbarrier + R circuit (130 Ω) 147mA and 0,9W => U= 24,48V => R = 166,6 Ω P = 24.482/(233,3+130) * ¼ = 0,5W Thermal resistance for SOT-23 package is 250K/W. Assessment for T4 classification according to component size ≤ 20mm

2 and surface temperature ≤ 275°C. : 250 * 0,54W = 135 and 135+75= 210 @Ta:

70˚C A.3.2 Wiring within apparatus No wiring within apparatus. A.3.3 Tracks on printed circuit boards Temperature classification of tracks on printed circuit board is evaluated out from the maximum permissible current in the circuit. Temperature classification T4 is accepted since the track width is minimum 0,2mm and the current is less than 1,8A.

A.4 Rating of components A.4.1 Resistors The listed resistors are infallible components according to clause 7.1 rating of components and 8.4 Current-limiting resistors. Safety factor 1,5 is included in the calculations. R32A-C & R33A-C, 6 x 22Ω, 1/4W 1% 0,9 / 6 *1,5 = 0,23W R1, 33kΩ 0,1W 0,1% Load: 28\33kΩ = 0,85mA => 0,852 x 33kΩ x 1.5 = 0,04W R2, 15kΩ 0,1W 0,1% Load: 28\15kΩ = 1,9mA => 1,92 x 15kΩ x 1.5 = 0,08W R5, R6, 10kΩ, 0.1W, 0.1% Load: 28/190+0,9*6*22+9,99KΩ x 1.5 = 0,11W. R19, 150kΩ, 0.1W 0.1% Load: 28

2/150kΩ x 2/3 = 0,008W

A.4.2 Shunt voltage limiters Not used in the circuit. A.4.4 __________ Not applicable. Not used.



A.5 Separation Distances

Component designation

Voltage zone [V] according to table 5.

Required separation [mm]

Measured separation [mm]

R32A-C 30 0,7 1,2

R33A-C 30 0,7 1,2

R1 30 0,7 1,2

R2 30 0,7 1,2

R5 30 0,7 1,2

R6 30 0,7 1,2

R19 30 0,7 1,2

PCB is coated. APPENDIX B: Tests Option 1: If tests records are provided as an attachment, please complete the following table:

Document number Number of Pages Name of Tests

-- -- --

-- -- --

-- -- --

Option 2: If tests records are not provided as an attachment, please complete the following table: B.1 Test conducted

Equipment Tested: GC-120

Date of Test (yyyy/mm/dd): Tested between 2004-02 and 2005-01-24 (Report 16224)

Clause and Standards: 10.1 (EN 60079-11: 2007 / IEC 60079-11: 2006)

B.1.1 Test procedures The voltage or current was increased to achieve the safety factor of 1,5 and the tests have been carried out according to IEC 60079-11 with 21% Hydrogen in air. The 95mH 30mA, 24V was used. B.1.2 Results Capacitors in the circuit: The sums of all capacitances are 67nF. Max permissible capacitance at 28V and 1.5X safety factor is 82nF. The internal capacitances are in series with the infallible resistors R32A-C (65Ω). The circuit is tested in the spark test apparatus: The capacitance 67nF serial connected with 65Ω was connected to an additional external capacitor of 50nF and charged to 28V x 1.5 = 42V. The 21% hydrogen mixture was not ignited during the 2,5 minutes(+) +2,5 minutes(-) test. The test was also performed with 60nF, but ignition occurred after 2 minutes.

ExTR Reference No. NO/NEM/ExTR12.0013/00FILE/IECEX_TR12.0013_60079_11.pdf · ExTR Reference No. NO/NEM/ExTR12.0013/00 TRF No. ExTR60079-11_5B-1 Page 2 of 13 IEC 60079-11 Clause Requirement

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