iecex.iec.chiecex.iec.ch/iecex/IECExWeb.nsf/0... · Web viewAbingdon,Oxon, OX14 1DY, United Kingdom Standard : IEC 60079-11:2006, 5th Edition Test procedure : IECEx System Test Report
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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.
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.
TRF No. ExTR60079-11_5B-1 Page 1 of 29
IECEx TEST REPORT IEC 60079-11
Explosive atmospheres – Part 11: Equipment protection by intrinsic safety "i"
5.1 General Refer to Appendix A.1 for details. PASS
5.2, 5.3, 5.4
Level of protection 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 Meets T4 (See Appendix A.3 Below) PASS
5.6.2 Temperature for small components
Meets T4 (See Appendix A.3 Below) PASS
5.6.3 Wiring within apparatus No Wires N / A
5.6.4 Tracks on printed circuit boards PCBs Awarded T4 As A Result Of Maximum Possible Power Dissipation In Any Component Or PCB Track = 0.62W < 1.25W (T4 @ +50°C) [Refer to Appendix A.3 Below]
PASS
Passed temp test on PCB track across battery: 57.5°C MAX MEASURED [Refer to Appendix B.3 Below]
PASS
5.7 Simple apparatus No Simple Apparatus N / A
6 APPARATUS CONSTRUCTION
6.1 Enclosures Enclosure Visually Meets IP20 PASS
6.1.1 Apparatus complying with Table 5 Adequate Separations Provided [Refer to Appendix B.1 Below]
PASS
6.1.2 Apparatus complying with Annex F Annex F Not Used N / A
6.2 Facilities for connection of external circuits
7.2 Connectors for internal connections, plug-in cards and components
No Plug-Ins N / A
7.3 Fuses No Fuses N / A
7.4 Primary and secondary cells and batteries
7.4.1 General UL Recognized Lithium Battery Cell PASS
7.4.2 Electrolyte leakage and ventilation No Electrolyte Leakage Observed During/Following Short Circuit Test [Refer to Appendix B.6 Below]
PASS
7.4.3 Cell voltages Values Per UL 60079-0 Used: 3.9Vpeak|3.6Vnom
PASS
7.4.4 Internal resistance of cell or battery
Cell Resistance Not Used N / A
7.4.5 Batteries in apparatus protected by other means of protection
No Associated Apparatus N / A
7.4.6 Batteries used and replaced in explosive gas atmospheres
No replaceable current-limiting devices N / A
7.4.7 Batteries used but not replaced in explosive gas atmospheres
Non-replaceable Battery Cell N / A
7.4.8 External contacts for charging batteries
No charging contacts N / A
7.4.9 Battery construction Battery Passed Spark Ignition And Temperature Testing [Refer to Appendix B.6 Below]
PASS
7.5 Semiconductors7.5.1 Transient effects No Transients – Battery Powered N / A7.5.2 Shunt voltage limiters See 8.6 Below PASS7.5.3 Series current limiters None N / A
7.6 Failure of components, connections and separations
All applicable faults considered/applied PASS
7.7 Piezo-electric Passed piezo testing [Refer to Appendix B.5 Below]
PASS
7.8 Electrochemical cells for the detection of gases
Gas Detectors Considered For Spark Ignition Contribution Based on Most Severe Parameters (See Appendix A Below)
PASS
8 INFALLIBLE COMPONENTS, INFALLIBLE ASSEMBLIES OF COMPONENTS AND INFALLIBLE CONNECTIONS ON WHICH INTRINSIC SAFETY DEPENDS
8.5 Blocking capacitors No Blocking Capacitors N / A
8.6 Shunt safety assemblies
8.6.1 General Adequately Rated Zener Diode Shunt Assembly Provided: D2/D3: Parallel Combination, Connected Such That Single Open Circuit Fault Simultaneously Disconnects Voltage Source
PASS
8.6.2 Safety shunts No Transients – Battery Powered N / A
8.6.3 Shunt voltage limiters No Transients – Battery Powered N / A
8.7 Wiring, printed circuit board tracks, and connections
No Infallible Connectors Provided: None Required
N / A
8.8 Galvanically separating components
8.8.1 General No Isolators N / A
8.8.2 Isolating components between intrinsically safe and non-intrinsically safe circuits
No Isolators N / A
8.8.3 Isolating components between separate intrinsically safe circuits
No Isolators N / A
9 DIODE SAFETY BARRIERS
9.1 General No Barriers N / A
9.2 Construction No Barriers N / A
9.2.1 Mounting No Barriers N / A
9.2.2 Facilities for connection to earth No Barriers N / A
Measurement Section, including Additional Narrative Remarks
APPENDIX A: Description of product
A.1 General overviewA.1.1 CIRCUIT DESCRIPTION (ST-Ex-H-C-001, Rev. 1.1 and/or Rev. 1.0):The product is battery powered (single ½ AA Size Lithium/Thionyl Chloride Cell). The battery includes solder tabs for both polarities. The solder tabs directly connect to the bottom of the PCB Assembly. There is only one PCB Assembly. The positive (+) battery has three separate branches through three current-limiting resistors (22Ω, ±5%, 1W, 2512): R37 makes supply “VD” (Only on Rev 1.1, Rev 1.0 makes “VM” directly from “VD”; All Analysis/Tests Based on Rev 1.1 which is Most Severe), R42 makes the “High Voltage Area” supply (Piezo Buzzer Circuit), and R44 makes supply “VM”. The “High Voltage Area” (Piezo Buzzer Circuit) includes a switched capacitor DC-DC Converter (U3) that drives the Piezo. The CPU14 connection of the “High Voltage Area” includes voltage clamping to prevent excessive voltages from becoming present on any other circuits. The maximum voltage inside the “High Voltage Area is limited only by the function of the switched capacitor DC-DC supply. Other than isolation/separations, there are no other protective features.
Passed Spark Test [See B6.2 Below] (PASS)2. Outside “High Voltage Area”VOC-MAX = 7.34V (High Voltage Out + Gas Sensor Out = 6V + 1.34V)ISC-MAX = 1.561A (Common Return + Gas Sensor Out = 0.561A + 1A)From Table A.1 (IEC 60079-11:2006): At I = 1.63A, V = 13.4V (IIC, x 1.5)
7.34V < 13.4V, 1.561A < 1.63A (PASS)3. Inside “High Voltage Area”VOC-MAX = 26.4VISC-MAX = 0.1AFrom Table A.1 (IEC 60079-11:2006): At I = 0.101A, V = 30V (IIC, x 1.5)
1. Capacitors at 3.9V (All Capacitors Shorted Between VD and Common)V-MAX = 3.9VI-MAX = 0.187AC-MAX = 31µFFrom Table A.1 (IEC 60079-11:2006): At V = 12.1V, I = 5A0.187A/5A = 0.0374From Table A.2 (IEC 60079-11:2006): At C = 32µF, V = 9.4V3.9V/9.4V = 0.415
0.0374 + 0.415 = 0.4524 = 2.2FOS > 1.5 (PASS)2. Capacitors at 6V (All Capacitors Shorted Between High Voltage Output and Common)V-MAX = 6VI-MAX = 0.0053AC-MAX = 30.5µFFrom Table A.1 (IEC 60079-11:2006): At V = 12.1V, I = 5A0.0053A/5A = 0.0011From Table A.2 (IEC 60079-11:2006): At C = 32µF, V = 9.4V6V/9.4V = 0.781
3. Capacitors at 7.34V (All Floating Caps Shorted Between High Voltage Output and Gas Sensor Output)V-MAX = 7.34VI-MAX = 1AC-MAX = 0.44µFFrom Table A.1 (IEC 60079-11:2006): At V = 12.1V, I = 5A0.0053A/5A = 0.0011From Table A.2 (IEC 60079-11:2006): At C = 32µF, V = 9.4V6V/9.4V = 0.781
0.0011 + 0.781 = 0.7821 = 1.27FOS < 1.5 Passed Spark Test [See B2.2 Below] (PASS)4. Capacitors at 13V (Capacitors Shorted Inside High Voltage Area)V-MAX = 13VI-MAX = 0.1AC-MAX = 0.44µFFrom Table A.1 (IEC 60079-11:2006): At V = 13V, I = 3.02A0.1A/3.02A = 0.0034From Table A.2 (IEC 60079-11:2006): At C = 0.442µF, V = 24.3V13V/24.3V = 0.54
0.0034 + 0.54 = 0.5434 = 1.84FOS > 1.5 (PASS)5. Capacitors at 26.4V (Piezo)V-MAX = 26.4VI-MAX = 0.1AC-MAX = 19.5nFFrom Table A.1 (IEC 60079-11:2006): At V = 26.4V, I = 0.207A0.1A/0.207A = 0.483From Table A.2 (IEC 60079-11:2006): At C = 40nF, V = 55V26.4V/55V = 0.48
0.483 + 0.48 = 0.963 = 1.034FOS < 1.5 Passed Spark Test [See B2.3 Below] (PASS)A.2.4 Combination of inductive and capacitive spark ignitionNAA.2.5 Shunt short-circuit (crowbar) spark ignitionNoneA.2.6 Other spark ignition considerationsNone
NO OTHER CIRCUITS REQUIRING SPARK IGNITION ASSESSMENT
A.3 Thermal ignition considerationA.3.1 Temperature for small componentsA.3.1.1 Components > 20SQ-MM: can be awarded T4 as the maximum dissipated power < 1.25W:
A.3.1.2 Components < 20SQ-MM: can be awarded T4 as the calculated temperature < 275°C:
A.3.2 Wiring within apparatusNoneA.3.3 Tracks on printed circuit boardsPCB can be awarded T4 as the maximum dissipated power < 1.25WPassed Temperature Test [See B3 Below] (PASS)A.3.4 Battery Cell:Passed Temperature Test [See B6.1 Below] (PASS)
NO OTHER CIRCUITS REQUIRING TEMPERATURE ASSESSMENT
Option 1: If tests records are provided as an attachment, please complete the following table:
Document number Number of Pages Name of TestsNA NA NA
Option 2: If tests records are not provided as an attachment, please complete the following table:
IEC 60079-0
Clause Requirement – Test Result – Remark Verdict
B1 Measurements of Separation DistancesEquipment Tested: Gas Detector; PCB Assembly
Date of Test (yyyy/mm/dd): 2011/March/29
Clause and Standards: 6.3 Separation distances; IEC 60079-11:2006
6.3 Test Procedure The separation distances in question were measured using various measurement means and tools including Documentation and Data, Calibrated Vernier Calipers, Rulers, Optical Loupe, and Gerber File Viewer Software. All measuring means and tools were verified by use of a calibrated Vernier Calipers and provided samples.
Test Equipment Calipers: N813S; Cal Due: 3/31/2011
Test Conditions NA
Acceptance criteria
6.3.1.1 Distances according to Table 5
For Circuits Up To 30V:
Per Table 5 (IEC 60079-11:2006):
Required Clearance: 2.0mm;
Required Creepage Distance: 2.0mm;
Required Distance Through Solid Insulation: 0.5mm
Test Results
6.3.2 Voltage between conductive parts
The maximum possible potential difference in the product is 26.4V < 30V
PASS
6.3.3 Clearance Minimum Measured Clearances Across Current Limiting Resistors:
R42 = > 2.5mm
R37 = > 2.5mm
R44 = > 2.5mm
PASS
6.3.5 Separation distances through solid insulation
Minimum Measured Separation Distances Through Solid Insulation Across Current Limiting Resistors:
R42 = > 0.5mm
R37 = > 0.5mm
R44 = > 0.5mm
PASS
6.3.7 Creepage distance Minimum Measured Creepage Distances Across Current Limiting Resistors:
Equipment Tested: Gas Detector, Simulated Circuits
Date of Test (yyyy/mm/dd): 2011/May/5Clause and Standards: 10.1 Spark ignition test; IEC 60079-11:2006
10.1 Test Procedure The necessary circuit was simulated using DC Power Supply, Capacitance Substitution Box, and Non-Inductive Resistors. The simulated circuit was spark tested, accordingly. The spark test gas was 21±2% Hydrogen in Air. The spark ignition test sequence was comprised of the following (Cal circuit consisted of 24VDC Supply and 95mH Inductor):
1. Calibration/Verification Of Test Gas Mixture;2. Spark Ignition Test (Positive Polarity);3. Spark Ignition Test (Negative Polarity);4. Calibration/Verification Of Test Gas Mixture.
Test Equipment RCL Meter: R162; Cal Due: 6/18/2011
Environmental Monitor: T1256; Cal Due: 10/12/2011
Timer: Q107; Cal Due: 1/10/2012
Rev Counter: Q108; Cal Due: 1/10/2012
Flow Meter: F263; Cal Due: 8/24/2011
Multimeter: M075S; Cal Due: 1/13/2012
Multimeter: M065S; Cal Due: 6/9/2011
Multimeter: M135S; Cal Due: 6/18/2012
Oxygen Analyzer: O193; Maintenance: 2/12/2011
Test Conditions Temperature: 24.5°CHumidity: 28%Pressure: 947hPa
Acceptance criteria
10.1 Spark ignition test No ignition of test gas
10.1 Test Results Test Voltage: 9V(= 1.5 x 6V);Test Current: 5.3mA;Test Capacitance: 30.5µF;1. Calibrate Before Test (30-31mA):
Ignition At: 1 Second;2. Positive Polarity:
No Ignition At 204 Revs;3. Negative Polarity:
No Ignition At 205 Revs;4. Calibrate After Test (30-31mA):
Equipment Tested: Gas Detector, Simulated Circuits
Date of Test (yyyy/mm/dd): 2011/May/5Clause and Standards: 10.1 Spark ignition test; IEC 60079-11:2006
10.1 Test Procedure The necessary circuit was simulated using DC Power Supply, Capacitance Substitution Box, and Non-Inductive Resistors. The simulated circuit was spark tested, accordingly. The spark test gas was 21±2% Hydrogen in Air. The spark ignition test sequence was comprised of the following (Cal circuit consisted of 24VDC Supply and 95mH Inductor):
1. Calibration/Verification Of Test Gas Mixture;2. Spark Ignition Test (Positive Polarity);3. Spark Ignition Test (Negative Polarity);4. Calibration/Verification Of Test Gas Mixture.
Test Equipment RCL Meter: R162; Cal Due: 6/18/2011
Environmental Monitor: T1256; Cal Due: 10/12/2011
Timer: Q107; Cal Due: 1/10/2012
Rev Counter: Q108; Cal Due: 1/10/2012
Flow Meter: F263; Cal Due: 8/24/2011
Multimeter: M075S; Cal Due: 1/13/2012
Multimeter: M065S; Cal Due: 6/9/2011
Multimeter: M135S; Cal Due: 6/18/2012
Oxygen Analyzer: O193; Maintenance: 2/12/2011
Test Conditions Temperature: 24.5°CHumidity: 28%Pressure: 947hPa
Acceptance criteria
10.1 Spark ignition test No ignition of test gas
10.1 Test Results Test Voltage: 11.01V(= 1.5 x 7.34V);Test Current: 1A;Test Capacitance: 0.44µF;1. Calibrate Before Test (30-31mA):
Ignition At: 13 Seconds;2. Positive Polarity:
No Ignition At 201 Revs;3. Negative Polarity:
No Ignition At 202 Revs;4. Calibrate After Test (30-31mA):
Equipment Tested: Gas Detector, Simulated Circuits
Date of Test (yyyy/mm/dd): 2011/May/5Clause and Standards: 10.1 Spark ignition test; IEC 60079-11:2006
10.1 Test Procedure The necessary circuit was simulated using DC Power Supply, Capacitance Substitution Box, and Non-Inductive Resistors. The simulated circuit was spark tested, accordingly. The spark test gas was 21±2% Hydrogen in Air. The spark ignition test sequence was comprised of the following (Cal circuit consisted of 24VDC Supply and 95mH Inductor):
1. Calibration/Verification Of Test Gas Mixture;2. Spark Ignition Test (Positive Polarity);3. Spark Ignition Test (Negative Polarity);4. Calibration/Verification Of Test Gas Mixture.
Test Equipment RCL Meter: R162; Cal Due: 6/18/2011
Environmental Monitor: T1256; Cal Due: 10/12/2011
Timer: Q107; Cal Due: 1/10/2012
Rev Counter: Q108; Cal Due: 1/10/2012
Flow Meter: F263; Cal Due: 8/24/2011
Multimeter: M075S; Cal Due: 1/13/2012
Multimeter: M065S; Cal Due: 6/9/2011
Multimeter: M135S; Cal Due: 6/18/2012
Oxygen Analyzer: O193; Maintenance: 2/12/2011
Test Conditions Temperature: 24.5°CHumidity: 28%Pressure: 947hPa
Acceptance criteria
10.1 Spark ignition test No ignition of test gas
10.1 Test Results Test Voltage: 39.6V(= 1.5 x 26.4V);Test Current: 0.1A;Test Capacitance: 19.5nF;1. Calibrate Before Test (30-31mA):
Ignition At: 2 Seconds;2. Positive Polarity:
No Ignition At 202 Revs;3. Negative Polarity:
No Ignition At 210 Revs;4. Calibrate After Test (30-31mA):
B3 Temperature TestingEquipment Tested: Gas Detector, PCB Assembly
Date of Test (yyyy/mm/dd): 2011/May/5Clause and Standards: 10.2 Temperature tests; IEC 60079-11:2006
10.2 Test Procedure As a result of inadequate spacing between R44 and Common (Rev 1.1), a short circuit between + Battery and –Battery can be imposed. This results in a PCB Track being subjected to unlimited battery short circuit current. A fully populated PCB Assembly (Battery Powered) was subjected to a direct short circuit across the +Battery and –Battery at the point discussed above. During the application of the short circuit, the temperatures of the PCB track in question were measured and recorded.
Test Equipment Data Logger: T1159; Cal Due: 3/16/2012
Environmental Monitor: T1256; Cal Due: 10/12/2011
Test Conditions Temperature: 24.5°CHumidity: 28%Pressure: 947hPa
10.2 Acceptance criteria Maximum allowed temperature (for T4/135°C) = 125°C (Accounts for required 5K safety margin for type testing and 5K for measurement uncertainty).
10.2 Test Results PCB Track Measured Maximum Temperature, Adjusted for +50°C Ambient = + 57.5 ° C .
Date of Test (yyyy/mm/dd): 2011/MAY/9Clause and Standards: 10.7 Tests for apparatus containing piezoelectric devices;
IEC 60079-11:2006
10.7 Test Procedure Two samples of the product (Gas Detector) were prepared with wires connected directly across the piezo in question. The capacitance value of the piezos were measured. Then the product samples were impacted tested at 0.7J in accordance with the “high” column of Table 8 (IEC 60079-0). The voltages across the piezos were measured during the impact test.
Test Equipment RCL Meter: M208; Cal Due: 10/1/2011
Environmental Monitor: T1256; Cal Due: 10/12/2011
Tape Measure: U058C; Cal Due: 4/19/2012
Oscilloscope: E055S; Cal Due: 4/20/2011
Scale: S222S: Cal Due: 4/25/2012
Test Conditions Temperature: 25°CHumidity: 29%Pressure: 947hPa
10.7 Acceptance criteria The maximum stored energy of the piezo, calculated using the following equation, E = 1/2CV2, shall not exceed 50µJ.
10.7 Test Results Impact Capacitance Voltage Energy PASSFront 13.56uF 25.83V 4.52µJ
IEC 60079-0Clause Requirement – Test Result – Remark VerdictB6 Cell Testing
B6.1 Electrolyte Leakage and TemperatureEquipment Tested: Cell; Vitzrocell, SB-AA02
Date of Test (yyyy/mm/dd): 2011/March/16
Clause and Standards: 10.5.2 Electrolyte leakage test for cells and batteries,10.5.3 (b) …Surface temperature of cells and batteries,10.2 Temperature tests;IEC 60079-11:2006
Test Procedure
10.5.2 Electrolyte leakage test for cells and batteries
Ten (10) samples of the cell in question had all outer insulators removed. Each cell was placed on white paper and then short circuited using a shunt having a resistance less than 3mΩ. The short circuit remained applied until the cell was discharged. The cells remained on the blotting paper for at least 12 hours following completion of the short circuit. During the short circuit application, the cell temperatures (Per 10.2) and short circuit current were recorded.
10.5.3 (b) Temperature of cells and batteries
Test Equipment Multimeter: M135S; Cal Due: 6/18/2011Environmental Monitor: T1256; Cal Due: 10/12/2011Data Logger: T1044; Cal Due: 1/11/2012Low Resistance Meter: B030S; Cal Due: 4/27/2011
Test Conditions Temperature: 23°CHumidity: 31%Pressure: 946hPa
Acceptance criteria
10.5.2 Electrolyte leakage test for cells and batteries
No allowed leakage
10.5.3 (b)10.2
Temperature of cells and batteries
Maximum allowed case temperature (for T4/135°C) = 125°C (Accounts for required 5K safety margin for type testing and 5K for measurement uncertainty).
Test Results
10.5.2 Electrolyte leakage test for cells and batteries
For all ten (10) cells, no venting, leakage, rupture, or electrolyte on the blotting paper observed.
PASS
10.5.3 (b) Temperature of cells and batteries
Sample ISC Max Temperature[Adjusted For +50°C Ambient]
Clause and Standards: 10.5.3 (a) Spark ignition…of cells and batteries10.1 Spark ignition test;IEC 60079-11:2006
Test Procedure
10.5.3 (a) Spark ignition of cells and batteries
Samples of the cells were spark tested (Per 10.1) using the enhanced gas mixture for Group IIC (60±0.5% Hydrogen in 40±0.5% Oxygen) to provide for the necessary 1.5 factor of safety. In accordance with UL 913, Edition 5; four (4) cell spark ignition trials using new cells were performed. The spark ignition test sequence was comprised of the following (Cal circuit consisted of 24VDC Supply and 95mH Inductor):
1. Calibration/Verification Of Test Gas Mixture;2. Spark Ignition Test Of new Cell (Positive Polarity);3. Spark Ignition Test Of new Cell (Negative Polarity);4. Spark Ignition Test Of new Cell (Positive Polarity);5. Spark Ignition Test Of new Cell (Negative Polarity);6. Calibration/Verification Of Test Gas Mixture.
Test Equipment Multimeter: M065S; Cal Due: 6/9/2011Environmental Monitor: T1256; Cal Due: 10/12/2011Timer: Q107; Cal Due: 1/10/2012Rev Counter: Q108; Cal Due: 1/10/2012Flow Meter: F263; Cal Due: 8/24/2011Multimeter: M075S; Cal Due: 1/13/2012Oxygen Analyzer: O193; Maintenance: 2/12/2011
Test Conditions Temperature: 24°CHumidity: 26%Pressure: 951hPa
Acceptance criteria
10.5.3 (a),10.1
Spark ignition of cells and batteries
No ignition of test gas
Test Results
10.5.3 (a) Spark ignition of cells and batteries
1. Calibrate Before Test (20-21mA):Ignition At: 20 Seconds / 24 Revs;
2. Positive Polarity (1):No Ignition At 209 Revs;
3. Negative Polarity (1):No Ignition At 204 Revs;
4. Positive Polarity (2):No Ignition At 204 Revs
5. Negative Polarity (2):;No Ignition At 202 Revs;
6. Calibrate After Test (20-21mA):Ignition At: 19 Seconds / 22 Revs.