Shunt -Di ode S afet y B arriers and Ga l van ic Iso l a t ors a Critic a l Comparison

By L C Tow l e BSc CEng M I Me c hE M IEE M Inst M C Te c hno l ogy D ire c t or The M TL Instruments G roup p l c

TP1113-2 June 1996

Introducti on
The d isc ussi on on the re l a t i ve meri ts o f g a lvan ic iso l a t ors and shunt d i ode s a f e t y b arri ers ha s been c arri ed on f or many ye ars . The ma j ori t y o f o ther ar t ic l e s on th is sub j e c t have a imed t o prove the superi ori t y o f one t e c hn i que over the o ther. Th is p a per bri ng s t oge ther the i llustra t i ons wh ic h have a cc umul a t ed over a c onsi dera b l e t ime i n re s pons e t o vari ous que st i ons ra is ed a t pre s ent a t i ons . It a tt emp ts t o ma k e b a l an c ed arguments s o tha t the re a der c an de ci de the mo st su i t a b l e t e c hn i que f or a p ar t ic ul ar a pp l ic a t i on . It end s w i th a sc ore shee t wh ic h mi ght be f ound us e ful i f a de cisi on is no t c omp l e t e l y s e l f reve a l i ng . The p a per ha s evo lved over a c onsi dera b l e t ime , however i t is un l ik e l y tha t i t c overs a ll a s pe c ts and w i ll i nev i t a b l y need t o be rev is ed a s t e c hn i que s deve l op . If you have any c omments on the c ont ents or omissi ons w i th i n th is do c ument the author woul d l ik e t o re c e i ve them . In th is w ay the do c ument w i ll be c ome more c omprehensi ve and more va lua b l e .

Fi g s 1 and 2
The b a sic fun c t i on o f an i ntri nsic a ll ys a f e i nt er f a c e is t o remove the ne c e ssi t y f or c er t i f y i ng the s a f e - are a equ i pment . The equ i pment i n the s a f e are a is usua ll y c omp l ex , need s t o be f l ex i b l e and c ont a i ns c onsi dera b l e power. There f ore i t c an i n j e c t si gn i f ic ant l eve ls o f energy i nt o the ha z ardous are a , p ar t ic ul arl y under f aul t c ond i t i ons . An i de a l i nt er f a c e a ll ow s the norma l l ow energy si gna l t o p a ss w i th a s sma ll a vo l t a ge drop a s po ssi b l e and w i th very l i ttl e a tt enua t i on . If however a f aul t deve l op s i n the s a f e - are a equ i pment then the i nt er f a c e c hange s i ts transf er c hara c t erist ic and re stric ts the energy transf erred t o the ha z ardous are a t o a s a f e l eve l . Shunt- d i ode s a f e t y b arri ers were deve l oped i n the l a t e 1 9 5 0s a s pro c e ss c ontro l c omput ers were more w i de l y a pp l i ed t o the c hemic a l i ndustry and are genera ll y reg arded a s be i ng the o l der t e c hn i que . However, i ntri nsic a ll y-s a f e re l ay is o l a t ors f or s w i t c h i nputs have been ava i l a b l e f or many ye ars (qu i t e how many I have no t been a b l e t o e st a b l ish) and ana l ogue is o l a t ors were ava i l a b l e i n 1 9 5 3 . The re c ent grow th i n the us e o f bo th t ype s o f iso l a t ors ha s re sul t ed from improved per f orman c e and l ower c o st , no t t o any c hange i n fund ament a l pri n ci p l e s .
HAZARDOUS AREA SAFE AREA

Certified hazardous area apparatus

Separately or together

Certified interface

Uncertified simple apparatus

Uncertified safe area apparatus eg: Computer

Um: 250v

Intrinsically safe interface

Barriers
Concept 1958 Redding Approved 1961 Gresham Kent

Isolators
Switch Analogue Telemechanique 1950's Pepperl & Fuchs Evershed & Vignoles 1953 MTL 1974

History

Fi g 3 and 4
F i g 3 i llustra t e s how a shunt d i ode s a f e t y b arri er is c onstru c t ed s o a s t o l imi t the c urrent and vo l t a ge ava i l a b l e from the ha z ardous- are a t ermi na ls . The fus e re stric ts the f aul t power, the z eners re stric t the vo l t a ge and the c urrent l imi t i ng re sist or [C LR] re stric ts the c urrent .
HAZARDOUS AREA SAFE AREA

Intrinsic Safety earth

CLR RO IO VO

Barriers are usually described in terms of their safety parameters: 28V 93mA 300R is a common barrier safety description where VO = 28 volts Current Limiting Resistor (RO) = 300R

Shunt diode safety barrier

2

The g a lvan ic iso l a t or i llustra t ed i n F i g 4 bre a ks any d ire c t c onne c t i on be t ween s a f e - and ha z ardous- are a circ u i ts by i nt erpo si ng a l ayer o f i nsul a t i on be t ween the t wo . The power transf er is usua ll y v i a s ome f orm o f transf ormer and the re turn si gna l v i a an op t o c oup l er, transf ormer, or re l ay. The f i na l power l imi t a t i on is a c h i eved by usi ng a d i ode re sist or ne t work very simi l ar t o tha t o f a shunt- d i ode b arri er.
Hazardous area connection
HAZARDOUS AREA SAFE AREA

Energy-limiting

Hazardous area circuit

S A F E T Y S E G R E G A T I O N

Certified component

Safe area circuit

Safe area connection

Certified transformer

Power
4

Galvanic isolation

Fi g s 5 and 6
Si n c e the ha z ardous- are a circ u i t from an iso l a t or is no t d ire c tl y c onne c t ed t o the s a f e are a circ u i t , i t is usua l t o reg ard the fund ament a l a c t i on a s e ff e c t i ve l y b l o cki ng the ex c e ssi ve energy a t the l ayer o f i nsul a t i on . In pra c t ic e the 0V o f the i nstrument syst em is norma ll y re turned t o the neutra l st ar po i nt f or i nt er f eren c e avo i d an c e and s a f e t y re a s ons . The re sul t ant f aul t c urrent is thus re turned t o the neutra l st ar po i nt i n the usua l w ay, rup turi ng the pro t e c t i ve fus e and remov i ng the f aul t , i n a re l a t i ve l y short t ime . The c onvent i ona l f aul t c onsi dera t i on o f the shunt- d i ode b arri er is i llustra t ed i n F i g 6 where the f aul t c urrent is re turned t o the neutra l st ar po i nt w i th i n the s a f e are a i n mu c h the s ame w ay. The impor t ant d i ff eren c e is tha t the transi ent vo l t a ge d i ff eren c e be t ween the b arri er bus b ar and the neutra l st ar po i nt [X 1 X] is now transf erred t o the ha z ardous are a and hen c e must be re stra i ned t o a l ow l eve l [l e ss than 1 0V] . In c ons equen c e the bus b ar t o neutra l st ar po i nt bond on the shunt d i ode s a f e t y b arri er must be o f l ow re sist an c e and be s e c ure , si n c e i t is c ri t ic a l t o s a f e t y.
Isolated internal components Plant bond Barrier Busbar X1 L N E X Field mounted instrument Instrument system Isolated internal components Plant bond 0V Field mounted instrument Instrument system

Galvanic Isolator under fault condition

Barrier under fault condition

Fi g 7
F i g 7 l ists the re l a t i ve meri ts o f is o l a t ors and b arri ers and the si gn i f ic an c e o f the s e f a c t ors vari e s w i th the p ar t ic ul ar i nst a ll a t i on . The rema i nder o f the do c ument exp and s the s e po i nts o f c omp aris on s o tha t they c an e a c h be eva lua t ed .

Barriers
Simple
Versatile

Isolators
Complex low MTBF Application specific High dissipation (2VA) Separate power supply Wider range power supply

Low dissipation
Loop powered Tightly controlled supply Restricted voltage available in hazardous area

Higher voltage (power) available in both hazardous area and safe area
Lower packing density

Higher packing density

Safety earth fundamental Imposes a reference 0 volt on system Circuit must be isolated from earth in hazardous area

Safety earth reduced significance Isolation between signals

Circuit may be earthed at one point in hazardous area Lower accuracy and linearity (0.25%)

Accuracy and linearity higher (0.1%) Lower cost Good frequency response [100KHz]
Encapsulated , irrepairable

Increased cost Limited frequency response Can be repaired

Vulnerable to lightning and other surges. Acceptable solution in most parts of the world

Less vulnerable to lightning and other surges. Preferred solution in marine installations and Germanic zones of influence
7

Comparisons

Fi g s 8, 9 and 10
In genera l the l ower number o f c omponents and b a sic simp l ici t y o f the shunt- d i ode s a f e t y b arri er me ans they are c onsi dered t o be more re l i a b l e . A more a cc ura t e c omp aris on ha s t o c omp are the re l i a b i l i t y o f an is o l a t or w i th the b arri er p lus a dd i t i ona l c omponents requ ired t o a cc omp l ish the s ame fun c t i on . F or examp l e F i g s 9 and 1 0 show the usua l s w i t c h c ont a c t transf er usi ng a b arri er re l ay c omb i na t i on wh ic h shoul d be c omp ared w i th the more c omp l e t e fun c t i ons o f the is o l a t or. Th is redu c e s the a pp arent superi ori t y o f the b arri er.

Barriers
Simple

Isolators
Complex (low MTBF)

Isolator has more components, comparison should consider total functional components. Isolator less vulnerable to supply variations

(35 yrs with relay)

(70yrs)

(18yrs)
Comparisons
8

HAZARDOUS AREA

SAFE AREA

MTL 787S Diode Return Barrier

24V+

Field switch is normally closed, open on alarm

Relay coil

IS Bond

Switch with Zener Barrier: preferred solution

4

HAZARDOUS AREA

SAFE AREA

Line fault detect resistors

Load, alarm or shutdown circuits

Field switch is normally closed, open on alarm

Supply

Plant reference potential

Digital Input

Switch with Galvanic Isolator

10

Fi g s 11 and 12 and 16
In genera l b arri ers are more vers a t i l e than is o l a t ors . F or examp l e the M TL 7 8 7S b arri er o f F i g 1 6 is i dent ic a l w i th tha t us ed i n the s w i t c h a pp l ic a t i on of Fi g 9 . If the f l ex i b i l i t y o f b arri ers is exp l o i t ed t o s o lve a new a pp l ic a t i on then an ana l ysis t a ki ng i nt o a cc ount po ssi b l e re sist i ve drop s and l e a k a ge c urrents is de sira b l e , a s i nd ic a t ed i n F i g 1 6 . W henever a d i ff erent untri ed c omb i na t i on o f an i ntri nsic a ll y s a f e i nt er f a c e and f i e l d mount ed equ i pment is propo s ed , i t is a dv is a b l e t o try an experiment a l i nt erc onne c t i on under l a bora t ory c ond i t i ons . A s a t isf a c t ory tri a l i n c re a s e s the prob a b i l i t y o f the f i na l i nst a ll a t i on worki ng . F i g 1 2 show s an iso l a t or f or us e w i th a c onvent i ona l 4 t o 2 0mA transmi tt er. The is o l a t or is de si gned f or us e w i th th is t ype o f transmi tt er and is no t us e ful f or any o ther fun c t i on .
Power supply 4-20mA 17.5V 300R 28V Typically up to 800R
HAZARDOUS AREA SAFE AREA

Barriers
Versatile

Isolators
Application specific

Isolators usually designed to solve a particular problem with limited flexibility Barriers: more than one application, but require applicational analysis. Compatability trials desirable in both circumstances

Comparisons

11

Isolation Load

Power supply 20-35Vdc

Isolator for 2-wire transmitters

12

Fi g 13
Iso l a t ors requ ire a dd i t i ona l power wh ic h ut i l is e s s p a c e , d issi p a t e s more he a t and i n c re a s e s c o st . The us e o f a we ll vent i l a t ed (po ssi b l y f orc e vent i l a t ed) c a b i ne t be c ome s a ne c e ssi t y i f is o l a t ors are c l o s e l y p a ck ed . It must be remembered tha t f or bo th b arri ers and is o l a t ors the max imum permi tt ed amb i ent t empera ture is the a ir t empera ture immed i a t e l y a d j a c ent t o the a pp ara tus i. e . the t empera ture i nsi de the en c l o sure . Th is t empera ture may be ra is ed by o ther a d j a c ent e l e c tric a l equ i pment .

Barriers
Low dissipation

Isolators
High dissipation

Isolators require 1-2VA for added signal power Temperature rise in large cabinets can be a problem Barriers dissipate very little 500mW 500 isolators yield 1Kw 30C rise in 2 meter high unventilated rack

Comparisons

13

Fi g s 14, 15, 16, 17, and 18

Barri ers may have over-vo l t a ge pro t e c t i on t o c ount era c t l arge supp l y vari a t i ons but the pro t e c t i on a b s orb s l i ne vo l ts . C onvent i ona l b arri ers re stric t the ava i l a b l e ha z ardous- are a l i ne vo l ts . F or examp l e , the c onvent i ona l d i ode re turn b arri er transmi tt er c omb i na t i on o f F i g 1 6 ha s a max imum l i ne vo l t a ge drop o f 0 . 9V. By c omp arison the M TL 3 0 4 1 circ u i t o f F i g 1 7 ha s 5 . 5V ava i l a b l e f or l i ne vo l t a ge wh ic h re a d i l y permi ts the us e o f l oop powered l o c a l i nd ic a t ors a s shown i n the d i a gram .

Barriers
Loop powered Tightlycontrolled supply

Isolators
Separate power required Wide range power supply

Isolator - higher power available for both hazardous and safe area. Variable supply Barrier - dissipates some power but can be used in existing circuits

Comparisons

14

Barriers
Restricted voltage in hazardous area

Isolators
Higher voltage (power) available in hazardous area

Isolators inject voltage to replace losses Barriers absorb available voltage

Comparisons
6

15

A c t i ve b arri ers su c h a s the M TL 7 0 6 shown i n F i g 1 8 permi t more l i ne vo l t a ge and are t o l erant o f supp l y vo l t a ge vari a t i on . They c onsume a dd i t i ona l power, but o ff er an a l t erna t i ve t o is o l a t ors i f there is a strong pre f eren c e f or a b arri er so lut i on .
12V 4-20mA
HAZARDOUS AREA SAFE AREA

6.8V 340R max MTL 787S+

V+25.1V 26.0V

Instrument
1-5V 250R

20R + 0.9V 1.3V

0V

IS Bond

Transmitter with diode return barrier (MTL 787S) 16

HAZARDOUS AREA

SAFE AREA

12.73 C
1V 12V 4-20mA 17.5V Isolation 300R 28V 16V 4-20mA Power supply + 20-35V dc.

MTL 3041

Loop-powered 4-20mA Indicator

17

HAZARDOUS AREA

SAFE AREA

22V-35V
40mA max
Protect Regulate

50mA

TX
15V

300R 28V
Floating supply 4-20mA

250R load

IS Bond 0V

MTL 706 schematic

18

Fi g s 19 and 20
The number o f i nt er f a c e s wh ic h c an be mount ed i n a c a b i ne t is l arge l y de t ermi ned by the si z e o f c a b l i ng t o be a cc ommod a t ed and the degree o f a cc e ssi b i l i t y t o be a c h i eved . F a ci l i t i e s f or c ro ss w iri ng a ls o us e c onsi dera b l e amounts o f s p a c e . The numbers quo t ed are tho s e f or generousl y de si gned ra cks and h i gher densi t y c an be a c h i eved a t the expens e o f a cc e ssi b i l i t y and t empera ture ris e . The f i gure s ava i l a b l e do however demonstra t e the h i gher p a cki ng densi t y wh ic h c an be a c h i eved w i th b arri ers . The number o f me c han ic a l vari a t i ons ava i l a b l e i n bo th b arri ers and is o l a t ors is i n c re a si ng and e a c h ha s i ts p art ic ul ar meri ts . The d isc re t e us e o f mul t ic hanne l un i ts c an a ls o e ff e c t i ve l y i n c re a s e the number o f c hanne ls per c a b i ne t . However si ng l e l oop i nt egri t y is s a c ri f ic ed and some thought a s t o whe ther th is is si gn i f ic ant or no t is e ss ent i a l .

Barriers
High packing density

Isolators
Low packing density

Isolators physically larger than barriers For some functions barriers require additional equipment In practice rack size is affected by cable trunking, termination of screens and armour Traditionally U.K. barriers were busbar mounted DIN rail mounting for both barriers and isolators now commonplace Backplane mounting, with plug in facilities available for both interfaces Multichannel interfaces save space, but sacrifice individual loop integrity

Comparisons

19

Cabinet
600 x 600 x 2100mm without crosswiring

MTL 700 400 units MTL 7000 650 units MTL 3000 192 units allows for Power Supply MTL 4000 256 units

Interface Numbers in Cabinet

20

Fi g s 21, 22, 23, 24 and 25

There is norma ll y mu c h empha sis on the ne c e ssi t y f or c orre c t bond i ng o f the shunt- d i ode s a f e t y b arri ers 0 vo l t bus b ar. However the deve l opment o f the requ ired bond i ng syst em from F i g 2 2 show i ng the requ irements f or stru c ture , c omput er 0V and sc reen t o the sl i ghtl y mod i f i ed syst em o f F i g 2 3 i llustra t e s tha t there is no d i ff ic ul t requ irement . To avo i d si gn i f ic ant d i ff eren c e s w i th i n the ha z ardous are a the bond shoul d have a l ow re sist an c e [0 . 1 !] and be o f h i gh i nt egri t y. The
8

Barriers
Safety earth fundamental

Isolators
Safety earth has reduced significance

Isolators - require consideration of bonding of screens or bond for interference avoidance Barriers - return path for fault current essential

Comparisons

21

po ssi b i l i t y o f i nst a ll i ng a s e c ond l e a d (a s i nd ic a t ed by the bro k en l i ne) f or mon i t ori ng purpo s e s shoul d be c onsi dered . However the pre s en c e and i nt egri t y o f the bond is e ss ent i a l i n a ll t ype s o f i nst a ll a t i on . The is o l a t or bond i ng syst em i llustra t ed i n F i g 2 4 is i dent ic a l w i th tha t o f the non-ha z ardous syst em , but the 0V bond ha s some s a f e t y imp l ic a t i ons . The overa ll e ar th i ng syst em i llustra t ed i n F i g 2 5 empha sis e s tha t the i nstrument syst em bond i ng is on l y a p art o f the t o t a l syst em . The requ irements are on l y marg i na ll y a ff e c t ed by whe ther b arri ers or is o l a t ors are us ed .
0V 24V Computer

Standard bonding practice

22

Computer 24V

0V

HAZARDOUS AREA

SAFE AREA

Shunt diode safety barrier bonding system 23

HAZARDOUS AREA SAFE AREA

Galvanic Isolator 24V

0V

Galvanic isolator bonding system

24

Plant
Interface cabinet

Control room
System cabinets

Sub station transformer

Screen Luminaire Armour

Barrier 0V

Computer 0V

Motor

Electrical distribution busbar

0V Clean busbar

0V Power busbar

Plant bond (structure + conductors + soil) Lightning earth Power system earth

Plant bonding

25

Fi g s 26, 27 and 28
W here si gna ls have t o be transf erred a c ro ss a ha z ardous are a usi ng i ntri nsic a ll y-s a f e c a b l i ng , the pre f erred t e c hn i que is t o us e g a lvan ic iso l a t i on a t bo th end s . F i g 2 7 i llustra t e s a syst em frequentl y us ed be t ween ana l ys er hous e s and c ontro l room . If a si gna l ha s t o be transf erred t o a remo t e l o c a t i on i n the s a f e are a , F i g 2 8 , the us e o f an iso l a t or a t the i nt er f a c e remove s c on c ern over po ssi b l e po t ent i a l d i ff eren c e s be t ween e ar th ma ts . The ex tra vo l t a ge needed t o dri ve the i nt erc onne c t i ng c a b l e s is a ls o us e ful . F or the s e re a s ons is o l a t ors are the pre f erred so lut i on , i n the s e p ar t ic ul ar circ umst an c e s .
SAFE AREA HAZARDOUS AREA SAFE AREA

Barriers
Imposes a reference 0 volt on system

Isolators
Isolation between signal and power supply

Isolators usually have 3 port isolation. Interaction between circuits reduced. Fault mechanisms easier to define Barrier 0 volt and computer 0 volt usually interconnected. Two channel barriers create pseudo 'earth free' circuits Barrier circuits bonded at barrier '0' volt, hence must be isolated elsewhere. Isolation necessary for transfer across a hazardous area or to remote situation

Comparisons

26

MTL 3058 (RS232C) or MTL 3059 (RS422A)

RS232orRS422 linkto processcontroller

MTL 3058 (RS232C) or MTL 3059 (RS422A)

RS232orRS422 linkto processcontroller

Tx Rx

Tx Rx
Common

20-35V dc

20-35V dc

Serial data transfer across a hazardous area 27

10

HAZARDOUS AREA

SAFE AREA

Plant Data Collection Centre

Remote Computer Centre Distance > 200m

Plant Supply Plant Mains Supply Plant Bond

0V

Signal transfer to remote computer

28

Fi g 29
There is a genera l requ irement tha t i ntri nsic a ll y-s a f e circ u i ts shoul d be e ar thed a t one po i nt on l y and e ls ewhere is o l a t ed t o w i thst and a 5 0 0V i nsul a t i on t e st . It f o ll ow s tha t where a s ens or or some o ther f i e l d a pp ara tus c anno t be i nsul a t ed (eg . a pH s ens or) then the pre f erred s o lut i on is t o us e an iso l a t or. In s ome c ountri e s the c ode o f pra c t ic e permi ts the usi ng o f equ i po t ent i a l bond i ng c ondu c t ors but th is is no t a un i vers a ll y a cc ep t ed pra c t ic e and shoul d be avo i ded i f a t a ll po ssi b l e .

Barriers
Circuit must be isolated from earth in the hazardous area

Isolators
Circuit may be earthed at one point in hazardous area

Requirement of intrinsically safe circuits Earthed at one point only Elsewhere insulated to 500V If sensor already earthed eg. bonded thermocouple, best to use an isolator Universally accepted Barriers can be used with potential equalising conductor in some countries (eg UK), but messy

Hazardous area isolation

29

Barriers
Accuracy (0.1%) and linearity higher

Isolators
Accuracy and linearity lower (0.25%)

Isolator process for analogue signals has several conversions. hence lower accuracy Barrier does not distort current signals. Leakage currents very small Digital signals do not lose accuracy

Comparisons

30

11

Fi g s 30, 31, 32 and 33

A l though the c hang i ng t e c hno l ogy o f is o l a t ors ha s i n c re a s ed the ir a cc ura c y, they are i n genera l l e ss a cc ura t e than b arri er syst ems . U sua ll y transf er a cc ura c y is a dequa t e but the t empera ture c oe ff ici ent rema i ns si gn i f ic ant . F i g s 3 1 and 3 2 show c omp ara b l e l oa d c e ll syst ems where every e ff ort is ma de t o a c h i eve max imum a cc ura c y. The b arri er l oa d c e ll syst em c an a c h i eve 0 . 0 5 % w i thout d i ff ic ul t y, and the is o l a t or syst em woul d a c h i eve 0 . 2 5 % i f the amb i ent t empera ture vari ed by 2 5C . F i g 3 3 show s a Smar t transmi tt er wh ic h when us ed w i th a 4 t o 2 0mA ana l ogue si gna l woul d expe c t t o genera t e a 0 . 2 % error a t the i nt er f a c e . If , however, the d i g i t a l repre s ent a t i on o f the me a surement w a s us ed then the is o l a t or woul d no t i ntrodu c e any error. It f o ll ow s there f ore tha t where is o l a t ors are the pre f erred s o lut i on f or us e w i th Smar t transmi tt ers and the h i ghe st a cc ura c y is requ ired then the d i g i t a l si gna l shoul d be us ed .
Multiple compensated load cells Certified Interface
+20 to 35V 0V

HAZARDOUS AREA

SAFE AREA

Line loss variation

End-to-end resistance variation Supply

Constant excitation voltage No voltage drop due to high impedance circuits

Sense

Signal 0V

6-wire connection minimised error

31

HAZARDOUS AREA

SAFE AREA

Intrinsically safe power supply

MTL3992

Intrinsically safe load cell power supply

32

HAZARDOUS AREA

SAFE AREA

HHC*

MTL4041

20-35V dc + I
4/20mA

Load

HHC* Smart transmitter *Hand-held communicator

Plug-in isolator with transmitter

12

33

Fi g s 34, 35 and 36
C o st c omp aris ons are a l w ays d i ff ic ul t be c aus e there is very rare l y a pre cis e c o i n ci den c e o f fun c t i on . There is however a genera l perc ep t i on tha t shunt d i ode s a f e t y b arri ers are l e ss expensi ve than iso l a t ors . In pra c t ic e f or s w i t c h transf er purpo s e s there is l i ttl e d i ff eren c e i n c o st per c hanne l be t ween the t wo t e c hn i que s . If i nd i v i dua l l oop i nt egri t y and mi n imum f a ci l i t i e s are a cc ep t a b l e the mul t ic hanne l s w i t c h is o l a t ors are l ower i n c o st than c orre s pond i ng b arri er so lut i ons a s i llustra t ed i n F i g 3 5 . Ana l ogue is o l a t ors are more c omp l ex than the c orre s pond i ng b arri ers and the c o st d i ff eren c e be c ome s si gn i f ic ant a s shown i n F i g 3 6 . However, ex c ep t f or very l arge i nst a ll a t i ons the c o st d i ff eren c e is rare l y the de ci d i ng f a c t or.

Barriers
Lower cost

Isolators
Increased cost

Isolators for analogue signals more expensive than barriers Switch inputs cost difference small. Possibly lower cost per channel with isolators

Comparisons

34

50
Cost per channel MTL 787S Shunt diode barrier

Single channel Isolator

Two channel Isolator

Cost of switch interfaces

Three channel Isolator

35

100
MTL 3046B Smart isolator

50
MTL 787S Shunt diode barrier

Cost of analogue transmitter interfaces

MTL 706 Actice shunt diode barrier

MTL 3041 Isolator

36

13

Fi g 37 and 38
In genera l the frequen c y re s pons e o f a b arri er is de t ermi ned by the va lue o f the c urrent l imi t i ng re sist or and the d i ode c a p a ci t an c e . The d i ode c a p a ci t an c e is non-l i ne ar w i th vo l t a ge and hen c e s ome d ist or t i on o f any h i gh frequen c y si gna ls i nev i t a b l y t a k e s p l a c e and a d isc ussi on on frequen c y re s pons e c an be misl e a d i ng . If a syst em frequen c y is h i gher than 5 0 k H z the on l y s o lut i on is t o try the syst em experiment a ll y, a tt emp t i ng i f po ssi b l e t o a ll ow f or the e ff e c ts o f i nt erc onne c t i ng c a b l es. Iso l a t ors i n genera l have t o be de si gned t o opera t e a t the s pe ci f ic frequen c y transmi tt ed . F or examp l e , w i th Smar t transmi tt ers the i nt er f a c e M TL 3 0 4 6B i llustra t ed i n F i g 3 8 works w i th the ma j ori t y o f transmi tt ers , but no t a ll . It is there f ore e ss ent i a l t o c he ck c omp a t i b i l i t y be t ween the p ar t ic ul ar a pp ara tus and the is o l a t or t o be us ed .
4/20mA
15V 300R 28V

Barriers
Good frequency response

Isolators
Limited frequency

Isolators - limited frequency spectrum Designed for specific frequency band Barriers - 3dB at 100khz Note: Diode capacitance is non linear with voltage

Comparisons

37

HAZARDOUS AREA

SAFE AREA

HHC*

MTL3046B
Isolation

HHC*

Load

Power supply 20-35V dc

*Hand-held communicator

Isolating interfaces for smart transmitters

38

Fi g 39
In genera l rep a ir is no t a pra c t ic a l propo si t i on . Some thought on the a cc ep t a b i l i t y o f b arri ers w i th i nt erc hange a b l e fus e s need s t o be g i ven i f frequent d ama ge is ant ici p a t ed and c anno t be avo i ded .

Barriers
Encapsulated

Isolators
Can be repaired

Isolators usually have fused primary and can theoretically be repaired Usually not economic Barriers encapsulated, hence throw away item

Comparisons
14

39

Fi g s 40, 41 and 42
W here there is a si gn i f ic ant prob a b i l i t y o f po t ent i a l d i ff eren c e s a c ro ss a p l ant due t o s evere e l e c tric a l f aul ts or l i ghtn i ng then iso l a t ors have gre a t er immun i t y t o d ama ge . F i g 4 1 i llustra t e s a po ssi b l e prob l em w i th b arri ers . A f aul t c urrent from the e l e c tric mo t or re turns v i a the p l ant bond genera t i ng a vo l t a ge be t ween po i nts X and Y. If th is is the c a s e , bre a k down o cc urs be t ween the thermo c oup l e and t an k c re a t i ng a po t ent i a l ha z ard . The shunt d i ode b arri er w i ll s a c ri f ici a ll y pro t e c t the i nstrument a t i on . Intri nsic a ll y-s a f e iso l a t ors are rout i ne l y t e st ed t o w i thst and 2 . 5 k V rms and hen c e o ff er s ome degree o f pro t e c t i on t o the i nstrument a t i on syst em . F i g s 4 2 show s how the us e o f an iso l a t or t oge ther w i th a su i t a b l e surge suppre ssi on ne t work c an prevent an una cc ep t a b l e vo l t a ge d i ff eren c e o cc urri ng w i th i n the Zone 0 .
Zone O THC X Vxy Shunt Diode Barrier Instrumentation Fault current Protective conductor and structural bond
HAZARDOUS AREA SAFE AREA

Barriers
Vulnerable to lightning and other surges

Isolators
Less vulnerable to lightning and other surges

Transient surges caused by lightning and faults in electrical apparatus cause potential differences across plant Equipment in Zone O principal cause for concern Barriers used with surge suppression units cause multiple earth problems

Comparisons

40

Protection Network

Shunt diode safety barrier fault current

41

HAZARDOUS AREA

SAFE AREA

100,000A Surge Suppression Network

Protective Network 1000V

Instrumentation

Zone O PE 10,000A

90,000A

Preferred isolator - surge protection solution 42

15

Fi g 43
The need t o mi n imis e the number o f t e c hn i que s us ed w i th i n an i nst a ll a t i on is obv i ous . U sua ll y there f ore , i f a p l ant a lre a dy us e s shunt- d i ode b arri ers or is o l a t ors i n mo st circ umst an c e s i t is be tt er t o ma i nt a i n a c onsist ent pra c t ic e .

If installation already exists and is predominantly a shunt diode safety barrier or an isolator installation then continue the same practice

1) Training of technicians 2) Spares 3) Mounting probably cheaper and more convenient

Overiding considerations

43

Fi g 44
H ist oric a ll y, the need t o avo i d circ ul a t i ng c urrent i n sh i p s hulls ha s l ed t o the pre f erred pra c t ic e o f usi ng is o l a t ed circ u i ts . In genera l usi ng shuntd i ode s a f e t y b arri ers doe s no t l e a d t o any prob l ems but the arguments are l ong and expensi ve . Simi l arl y, G erman eng i neers are tra i ned t o us e and pre f er g a lvan ic is o l a t ed circ u i ts .

Barriers
Acceptable in most areas of the world

Isolators
Preferred solution in marine installations and German zones of influence

Marine regulations propose isolated circuits to avoid currents in hull Easier to use isolators than argue about 2 channel barriers German attitude German engineers prefer galvanic isolation particularly in Zone 0 Easier to to agree than convert

Particular situations

44

Fi g s 45 and 46
The sc ore shee t s pri n ci p a l fun c t i on is t o ma k e sure you c onsi der e a c h o f the c ontri but i ng f a c t ors . If you have a pre f erred t e c hn i que then pursue tha t l i ne , si n c e e i ther s o lut i on w i ll prob a b l y be s a t isf a c t ory.

Allocate marks out of 10 if the requirement is important. eg. 8-2 Allocate marks out of 6 if the requirement is significant. eg. 2-4 Allocate no marks if the requirement has no significance. eg. 0-0 If total show a significant preference then follow the choice If the argument is balanced then follow your personal preference Whatever you do, use MTL equipment

Score sheet
16

45

Barriers
Prefer Barriers Existing system predominately barriers Simple Versatile Low dissipation Loop powered Tightly controlled supply Restricted voltage available in hazardous area Higher packing density Safety earth fundamental Imposes a reference 0 volt on system Circuit must be isolated from earth in hazardous area Accuracy and linearity higher (0.1%) Lower cost Good frequency response [100KHz] Encapsulated , irrepairable
Vunerable to lightning and other surges. Acceptable solution in most parts of the world Total

Rating

Isolators
Prefer Isolators Existing system predominately isolator Complex low MTBF Application specific High dissipation (2VA) Separate power supply Wider range power supply Higher voltage (power) available in both hazardous area and safe area Lower packing density Safety earth reduced significance Isolation between signals Circuit may be earthed at one point in hazardous area Lower accuracy and linearity (0.25%) Increased cost Limited frequency response Can be repaired

Rating

Less vulnerable to lightning and other surges. Preferred solution in marine installations and Germanic zones of influence Total

Score sheet

46

17