Intrinsic Safety Barriers Overview
Intrinsic Safety Barriers Overview
Section 9 Hazardous
Area
Safe Area, Div 2 or Zone 2 Product info. on
pgs. 301, 309
Practical Solutions Z787.*
Safe
Intrinsic safety barriers are the core of Pepperl+Fuchs product Plus
portfolio. We offer the widest selection of products for protection
of electrical signals located in hazardous (explosive) areas. This
guide presents common hazardous area applications involving
intrinsic safety barriers to assist in selecting the correct barrier for
your application.
By far, our most popular intrinsic safety barrier is the flexible,
DIN rail mounted K-System isolator. This product line consists
of over 150 different functional designs to meet the demands of
today’s factory and process automation industries. The unique Figure 9.1
design allows simple expansion with no additional wires, and can
be easily designed for several redundant power configurations. This illustrates an alternate method of providing mutlitple channels
K-System components meet SIL IEC61508 ratings to ensure in a “quasi-floating” configuration. The first channel of the Z787.*
conformity to international safety standards for systems and (or Z787.H.*) is used as the field power supply while each diode
processes. return channel is isolated from ground.
Zener diode barriers are the most economical hardware method
Hazardous Safe Area, Div 2 or Zone 2
available to solve a hazardous area barrier/intrinsic safety Product info. on
Area pgs. 300, 301, 309
application. Our SafeSnap series of zener barriers has over Z787.*
Z787.H.*
85 unique versions to solve your intrinsic safety application. Safe
SafeSnapPlus barriers contain a removable fuse that eliminates Plus
disassembly, disconnection of wiring or disposal of an entire
barrier in the event of a fault.
In addition to the intrinsic safety barriers presented in this
application guide, Pepperl+Fuchs also offers HiD2000, our line of
backplane mounted isolated barriers. This innovative product is
ideal for applications requiring tight DCS or system integration.
The powerful motherboard system is available in a wide range
of termination assembly versions that can be installed easily.
The intrinsic safety modules simply plug into the motherboard,
Z786
so wiring is never an issue on the barrier itself. Plus, HART
multiplexers can be integrated easily into a HiD2000 system once
the proper module is installed on the motherboard.
Also available is our µZ range of zener diode barriers that
combines outstanding features and performance in a compact
housing. Its thin width and low profile—the lowest profile zener
on the market—make it perfect for those hard-to-reach areas of
a cabinet or an enclosure. Plus, µZ comes with many of the great
features found in our full line SafeSnap product.
At Pepperl+Fuchs, we build and support quality products that
Figure 9.1
meet the demands of our customers and take intrinsic safety
well into the 21st century. Note: SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
barriers have internal fuses.
Switches and NAMUR Sensors
Product info. on Hazardous Area Safe Area, Div 2 or Zone 2 Product info.
pgs. 109, 110 on pg. 108
KFD2-SR2-Ex1.W
Input 1
1
}
8
R2 Relay
2 7
Output
R1 R1
3 9
LB/SC LB/SC LB
14 (+)
15 (–) } Supply
24 VDC
Collective Error Messaging
Power Rail Connection
Figure 9.3
Figure 9.7
}
8
1
R2 Relay
! 7
2 Output 1
R1 R1
3 9
LB/SC LB/SC LB 11
!
10
12
} Relay
Output 2
Signal or Error
!
14 (+)
15 (–) } Supply
24 VDC
Collective Error Messaging
Power Rail Connection
Dual Channel AC
Product info.
Hazardous Area Safe Area, Div 2 or Zone 2 on pg. 119
Product info. on
pgs. 115, 116 Input 1
4
R2
5 Active Transistor
7
R1 R1 Output 1
6
Active Transistor
LB/SC LB/SC LB
Output 2 Signal
9 or Error
14 (+)
15 (–) Supply
24 VDC
Collective Error Messaging
Power Rail Connection
Figure 9.10
Figure 9.5
Product info.
Product info. on Hazardous Area Safe Area, Div 2 or Zone 2 on pg. 121
pgs. 125, 126
Input 1
"!
7
# !
"!"!
R2
R1
1
2
8 (+/-)
Passive Transistor
Output 1
R1 Passive Transistor
3
Output 2 Signal or
# ! LB/SC LB/SC LB 9 Error
"! "!"!
"$
14 (+)
15 (–) Supply
24 VDC
Collective Error Messaging
Power Rail Connection
Hazardous Area Safe Area, Div 2 or Zone 2 Product info. Safe Area or Div 2 Product info.
on pg. 114 Hazardous Area on pg. 124
!#'&
[Link]
Input 1
)
'&#'& R2
R1 R1
1
3
7
8
10
}
}
Passive Transistor
Output 1
Passive Transistor
!#'& Output 2
11
) Input 2
'&#'& 4
R2
* '## )
R1 R1
5
6
14 (+)
15 (–) } Supply
24 VAC
LB/SC LB/SC LB
Quad Channel DC
Product info.
Hazardous Area Safe Area, Div 2 or Zone 2 on pg. 117
Safe Area or Div 2 Product info.
Input 1
on pg. 118
KFD2-SR2-Ex2.2S
&(,+ &(,+
/ /
/
1
}
7
Output 1
Channel 1
R2
2
8
Channel 2
/
#&&!%
R1 R1
9 /
/
#&&!%
3
}
10
Output 2
Channel 1
Input 2 11
/
#&&!%
Channel 2
#&&!%
&(,+ &(,+
12 /
4 /
/
R2
/
5
R1
}
R1 14 (+) /
Supply
6 /
$)! $)!
Collective Error Messaging
'%%! +$-!))')!**"$&"
Power Rail Connection
Power Rail Connection
6
14 (+)
15 (–) Supply
24 VAC
LB/SC LB/SC LB
Collective Error Messaging Hazardous Safe Area, Div 2 or Zone 2
Power Rail Connection
Product info. on
Area Z787.*
pgs. 301, 309
Figure 9.14
Safe
Replaceable
Plus Fuse
I/O
1 Resistor Fuse 8 +27 Vmax
Z-Diodes
Product info. 4-20 mA 2 7 Load 0V
Hazardous Area Safe Area, Div 2 or Zone 2 on pg. 120
Replaceable
3 Fuse 6
Input 1
Z-Diodes
1 4 5
R2 Resistor Diodes Fuse
2 Active Transistor
7
R1 R1 Output 1
3
IS Ground
Input 2
Active Transistor
4 9
Output 2
R2
5 Figure 9.18
LB/SC LB/SC
R1
LB
R1
6
14 (+)
15 (–) Supply
24 VDC
Figure 9.15
12
Hazardous Safe Area, Div 2 or Zone 2 Product info. on (+) 4 11 (+)
Area pgs. 299, 307
Z728.* (–) 6 10 (–) Load
Safe
Replaceable 14 (+)
Plus Fuse 15 (–) 24 VDC
I/O
1 Resistor Fuse 8 Load +27 Vmax
4-20 mA Z-Diodes
2 7
0V
Figure 9.22
If the I/O system requires a 1-5 V input, the Z788.R contains a Hazardous Safe Area, Div 2 or Zone 2 Product info.
on pg. 151
Area
precision 250 7 resistor internally connected between Terminals 3 KFD2-STC4-Ex1
and 4 to facilitate the 1-5 V output from a 4-20 mA transmitter.
9
Hazardous Safe Area, Div 2 or Zone 2 Product info.
on pg. 301 (+) 1 8
Area
Z788.R 2 7 4-20mA
S I/O
4-20 mA 3
Resistor Fuse 14 +
1 8 +27 Vmax
15
Z-Diodes
4-20 mA 2 7 V 0V
4
Z-Diodes
5
Figure 9.23
Resistor Fuse
IS Ground
Isolated Transmitter Power Supply
Figure 9.21
This figure shows a galvanically isolated transmitter power
Note: If additional voltage is required for the transmitter, the Z788.R.H can supply similar to Figure 9.23, except the safe area output sinks
provide the necessary increase. The entity parameters must, however, be the current from the I/O device. This barrier is suitable for SIL 2
verified. applications according to IEC 61508.
provides 3-way isolation between power, input and output for (+) 1 8
20-30 V
within a hazardous area and transfers the anlog 4-20 mA signal 4-20 mA 3
from the hazardous to the safe area. These barriers are suitable 14 +
Figure 9.24
9 I /O
8 (+)
Load IS Ground
(+) 1 7 (–)
2 12 Figure 9.27
11 (+) Load
4-20 mA 3
10 (–)
Note: When using zener barriers with SMART Transmitters, the over-all
14 (+)
24 VDC resistance for the loop must be considered to ensure correct operation.
15 (–)
SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
Power Rail Connection
barriers have internal fuses.
Figure 9.25
Figure 9.26
Power Rail Connection
Figure 9.28
The figure below shows an alternate method of achieving Note: Depending on calibrator design, connection can be made across
bidirectional SMART communication through a zener diode Terminals 9 and 10 in the safe area.
barrier. The circuit implementing the Z728.* zener barrier must
be individually isolated from each I/O channel or must have the
measurement load attached to the positive leg of the supply for
proper analog/digital communication to occur.
Product info. on
Hazardous Safe Area, Div 2 or Zone 2 pgs. 299, 307
Power Rail Connection
Area
Figure 9.30 Z728.*
Safe
Note: The KFD2-STC4-Ex1.20-Y112669 has sink mode outputs. Plus
Replaceable
Fuse
1 Resistor Fuse 8
Z-Diodes
2 7
Hazardous Safe Area, Div 2 or Zone 2 Product info. on
pgs. 155, 156
Area
I/O
9
(+) 1 8 (+)
Load
(–) 3 7 (–)
IS Ground
12
(+) 4 11 (+) Figure 9.33
(–) 6 10 (–) Load
Note: In order to conserve DIN rail space, the dual channel Z779.* could
14 (+) provide operation and protection for two I/P converters if the Z728.* is
15 (–) 24 VDC
acceptable.
Figure 9.31 A dual channel Z787.* can be used in situations where the return
line of the I/P cannot be connected to the earth ground. The
Note: The KFD2-STC4-Ex2-Y72195 has sink mode outputs
additional diode-return channel of the Z787.* provides isolation for
the 4-20 mA current.
Figure 9.34
Note: The KFD2-STC4-Ex1.20-Y112668 has sink mode outputs.
Note: SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
barriers have internal fuses.
Isolated Barriers
Isolated Current/Voltage Driver
The KFD2-CD-Ex1.32 driver barrier features high accuracy and
temperature stability. By special order both the input and output
of this galvanically isolated barrier can be altered to suit the
application. They can be independently configured for either
voltage or current. This module provides 3-way isolation between
power, input and output for superior signal integrity. This barrier is
suitable for SIL 2 applications according to IEC 61508.
Product info.
Safe Area or Div 2
Hazardous on pg. 183
Area
I/O
Power Rail Connection
250
9
8 (+)
Figure 9.35 (+) 1
Current
(–) 2
I
4-20 mA 7 (–) Source
250
Isolated Current Driver 12
(+) 4 11 (+)
The loop powered KFD0-CS-Ex1.51P barrier is galvanically 4-20 mA (–) 5 10 (–)
Current
I
Source
isolated making its application very simple. Although primarily 14 (+)
24 VDC
designed for fire detector applications where accuracy is much 15 (–)
Product info.
on pg. 192
Hazardous
Area
4-20 mA
Source
(–) 2
14 (+)
24 VDC
15 (-)
Figure 9.37
I
4-20 mA 7 (–)
Hazardous Product info. on Source
Safe Area, Div 2 or Zone 2 pgs. 301, 309
Area 250
Z787.* 12
(+) 4 11 (+)
Safe Current
Replaceable 4-20 mA (–) 5 10 (–)
I
Fuse
Source
Plus
14 (+)
1 Resistor Fuse 8 24 VDC
15 (–)
Z-Diodes
2 7
IS Ground Thermocouples
Figure 9.41
Zener Diode Barriers
Note: When using zener barriers with SMART I/P field devices, the over-all
resistance for the loop must be considered to ensure correct operation. This is most common method of connecting a thermocouple to
SafeSnapPlus zener barriers are designed with replaceable fuses which a zener diode barrier. The dual channel configuration provides
is denoted by an “F” at the end of the model number. SafeSnap zener a balanced circuit with a maximum of 64 7 in each channel,
barriers have internal fuses. allowing operation for any thermocouple type.
I/P converters in a hazardous location. The digital information
generated by the processing system, field device or hand-held
terminal is bidirectionally transferred by the barrier. This barrier is
suitable for SIL 2 applications according to IEC 61508.
4-20 mA
(–) 2
Source Isolated Barriers
14 (+)
Isolated Loop Powered Thermocouple Transmitter
24 VDC
15 (-) The loop powered KFD0-TT-Ex1 barrier is galvanically isolated
Collective Error Messaging
and provides a 4-20 mA output for multiple thermocouple inputs.
Power Rail Connection This barrier can be configured manually for the thermocouple type
and upscale or downscale burnout and is also provided with zero
Figure 9.42
and span point potentiometers.
Dual Channel Isolated SMART Current Driver Hazardous Safe Area, Div 2 or Zone 2 Product info.
on pg. 203
Area
The [Link] is a dual channel SMART current driver
barrier, and which provides 3 way isolation between power,
input and output. The isolator is designed to control SMART I/P I /O
Figure 9.45
Power Rail Connection
Figure 9.46
8 (+)
(+) 4
(+) 3 7 (–)
Load
(–) 2
(+) 1
RxD Programming
TxD
Jack
GND
11 (+)
24 VDC
12 (–)
Figure 9.49
Note: SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
barriers have internal fuses.
12-35 VDC 1
RxD Programming
1 TxD
Load (–) 2 GND
Jack
(–) 2 8 (–)
4-20 mA
11 (+)
24 VDC
12 (–)
Figure 9.52
Figure 9.51
Power Rail Connection
Figure 9.54
Z964
Note: Contact Pepperl+Fuchs regarding the availablity of the new
S KFD2-WAC2-Ex1 strain gauge converter.
350
Vibration Monitoring
Zener Diode Barriers
Z961.* This figure illustrates an example of a zener diode barrier and a
Safe vibration monitor in the hazardous area. The vibration monitor
Plus outputs a voltage signal, which is referenced to the positive
supply, proportional to the vibration waveform at frequencies up
to 4 kHz. Therefore, a negative polarity barrier is required and the
positive side of the power supply must be grounded.
Safe Area, Div 2 or Zone 2 Product info.
Hazardous on pg. 300
Area
Figure 9.53
Note: SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
barriers have internal fuses.
Figure 9.55
Hazardous Safe Area, Div 2 or Zone 2 Product info. Safe Area, Div 2 or Zone 2 Product info. on
Hazardous pgs. 305, 310
Area on pg. 172
Area
Safe
Replaceable
Plus
Fuse
Hazardous Safe Area or Div 2 Product info. Safe Area, Div 2 or Zone 2 Product info. on
Area on pg. 171 Hazardous pgs. 303, 311
KFD2-VR-Ex1.19-Y109129 Area
Safe
I/O
Plus
(+) 4 7 (–)
V
(–) 5 8 (+) 0…±10V
Measurement
11 (+)
24 VDC
12 (–)
Figure 9.57
Safe
Plus
Figure 9.59
Note: SafeSnapPlus zener barriers are designed with replaceable fuses which
is denoted by an “F” at the end of the model number. SafeSnap zener
barriers have internal fuses.
Replaceable
3 Fuse 6
Isolated Potentiometer Transmitter – Voltage Z-Diodes
4 5
The KFD2-PT2-Ex1, KFD2-PT2-Ex1-1, KFD2-PT2-Ex1-2 and Resistor Diodes Fuse
Isolated Barriers
Isolated Loop Powered Discrete Output Driver
The loop powered KFD0-CS-Ex1.51P barrier is a galvanically
isolated discrete output barrier. It can be used to energize certain
types of solenoids, LEDs and alarms. With a 24 V source, this
barrier will supply approximately 27 mA at 12 V to the hazardous
Power Rail Connection
area field instrument. This barrier is suitable for SIL 2 applications
Figure 9.61 according to IEC 61508.
Supply
24 VDC
Note: KFD2-SL2-Ex2.B is the basic unit and does not include such features as
Isolated Logic Input Solenoid Driver LB/SC monitoring or collective error massaging.
I/O
Hazardous Safe Area, Div 2 or Zone 2 Product info.
(+) 1 7 (+) on pg. 142
Area
Logic
(–) 2 8 (+/–) Input
(–) 3
I /O
Supply (+) 1
24 VDC
(–) 2 Logic
Input
Collective Error Messaging
(–) 3 Fault
Power Rail Connection
Output
Figure 9.68
Power Rail Connection
Figure 9.71
Resistor Fuse V
1 8
Z-Diodes
(–) 5 8 (+) 0…±10V
2 7 Measurement
11 (+)
Replaceable 24 VDC
3 Fuse 6 12 (–)
Z-Diodes
4 5
Resistor Diodes Fuse Power Rail Connection
Figure 9.72
IS Ground
Figure 9.74
Note: For AC Powered units ask for KFA5-DWB-Ex1.D (120 VAC) or KFA6-
DWB-Ex1.D (240 VAC). Collective error messaging and Power Rail Isolated Rotation Direction Indicator and
connection are not available on the AC units.
Synchronization Monitor
The galvanically isolated KFD2-UFT-Ex2.D comes with a
display for easy on site programming and is used when a
Isolated TimeDelay Relay rotation direction indicator or synchronization monitor is
The galvanically isolated KFD2-DU-Ex1.D comes with a needed. A non-display unit is available with the KFD2-UFT-Ex2.
display for easy on site programming and is commonly used in
applications requiring on delay, off-delay, one-shot or pulsating Hazardous Area Safe Area or Div 2 Product info.
signal conditioning.
on pg. 224
(+) 1 11
10 Output 1
RxD Programming 12
TxD
Safe Area, Div 2 or Zone 2 Product info. GND
Jack 17
Output 2
Hazardous Area 16
on pg. 213 18
KFD2-DU-Ex1.D (–) 3 19 (+)
Output 3
20 (–)
11 Output 4
(+) 4 21 (+)
(+) 1 10 Output 1 7 (–)
8 (+) Output 5
12
13
Reset Input 14
19 (+) 15
(–) 3 Output 2 23 (+) Supply
(–) 6 24 (–) 24 VDC
20 (–)
13 (+) Collective Error Messaging
Reset
14 (–) Power Rail Connection
23 (+)
Supply
24 (–) 24 VDC
Figure 9.77
Collective Error Messaging
Power Rail Connection Note: For AC versions of this unit ask for our universal power supply version
the KFU8-UFT-Ex2.D or the KFU8-UFT-Ex2. Collective error messaging &
Figure 9.75 Power Rail connection are not available on the universally powered units.
Note: For AC versions of this unit order the KFA5-DU-Ex1.D (120 VAC) or
the KFA6-DU-Ex1.D (240 VAC). The AC units are not equipped with
collective error messaging or Power Rail connection.
Input for
current supply
(–) 2
0-20 mA
4-20 mA
0-10 V
2-10 V
(+) 6
1
KFD2-GU-Ex1
RxD
TxD
GND
Programming
Jack 8
7 Output 1
(–) 3
(+) 4
7
9
} Output 1
2 11
}
Input for (–) 2 (+) 5
9
thermocouples
3 10 Output 2
Cold junction 11
compensation 4 (–) 6 12
K-CJC
10 Output 2
3-wire
5
6
12 14
15 } Supply
120VAC
Figure 9.78
7
0/4-20mA Output 3
(+) 1 (+) 1 8
11
2 2
10 Output 1
I
12
3 3 3 17
RxD 16 Output 2
TxD Programming
GND Jack 18
23
Supply
24 24 VDC
Figure 9.80
Power
24VDC 24VDC
Distribution 7 7
12 12
Power Feed with
12 11 11
Module Power Rail 10 10
24VDC 11
Figure 9.83
Note: PR-03 is a 500 mm insert for standard 35mm DIN Rail. UPR-03 is sold in Fault Signal Output Fault Signal Output
2 meter lengths and comes with its own 35 mm DIN Rail.
Figure 9.85
Fault Signal
7 24VDC 1 3
12 GND
2
10 11 L1 N 4 6
120/240VAC 24VDC
Figure 9.86
Fault Signal Output
Note: The number of isolators per power supply depends upon the power
Figure 9.84 consumption of each module.
Power Supply C
D
G E
125 mm
A - Cover
B - Two leads for power
14 120/240VAC
15 C - One conductor for collective error (UPR-03)
Figure 9.87 Three conductors for bus connection (UPR-05)
Note: The number of isolators per power supply depends upon the power
D - Universal Power Rail
consumption of each module. E - Mounting Holes
F - DIN Rail
G - End Cap UPR-E
Power Rail
A Note: The UPR-03 nd UPR-05 is two meters in length and comes with its own
PR-03/PR-05 35 mm DIN rail.
B
D
Note: PR-03 and PR-05 is a 500 mm insert for standard 35 mm DIN rail.
Individual sections can be connected with a VE-PR link.









