Intrinsically Safe Barrier Relays NY2 and 8501TO Class/File 8501 CONTENTS Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page NY2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 NY2 Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 NY2 SpeciŢcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 NY2 Approximate Dimensions and Wiring Recommendations. . . . . . . . . . . . . . . . . . 5 NY2 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8501TO General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 8501TO Ordering Information, Application Data, Approximate Dimensions. . . . . . . . 8 Intrisically Safe Barrier Relays NY2 – Relays For Hazardous Locations General Information Intrinsically Safe (IS) Explosion prevention is a prime consideration in plants and facilities containing hazardous atmospheres and explosion-proof housings. The main fault with the explosion-proof system is that a single human error could create a high explosion probability. Prime examples are failing to tightly replace covers on explosion-proof housings, failing to shut off the power before removing the covers, and damaging the specially machined surfaces of these covers. Intrinsically safe (IS) systems are a means of providing automated control functions in explosive environments. Because of the inherent parameters of electronic circuits, no energy is released, under normal or abnormal conditions, of sufŢcient magnitude to ignite a speciŢed atmosphere mixture. To design an effective intrinsically safe system, energy that enters the hazardous area must be limited. For electronic instrumentation, this is accomplished by controlling the voltages and currents that may enter the hazardous area. In addition, stored electrical energy in Ţeld instruments is limited to levels that cannot ignite a given atmosphere. Intrinsically safe relays, such as the NY2 and the Class 8501 Type TO relays, act as an energy barrier, limiting the voltage and current available in the hazardous area. They can be connected with any device having a dry contact (limit switch, magnetic switch, pushbutton, pneumatic-electric interfaces, etc.) or with NAMUR sensors. NAMUR sensors (NAMUR is a European standard) are solid state detectors speciŢcally designed to work with such a limited amount of voltage and current. All Telemecanique NAMUR sensors comply with the strict energy limitations imposed by intrinsically safe relays. NOTE: Compare the sensor characteristics with related input line parameters (page 4) to determine the maximum cable length allowed when using a particular cable brand. For battery applications, a DC to AC converter (NY2 K10) is used to power up to four IS relays. This solution is safer than using DC barriers since it offers physical isolation between hazardous and non-hazardous areas. Non-incendive switches for hazardous areas A wide variety of indexing head surface mounted and tubular proximity switches have Factory Mutual approval for installation without any immediate barrier or control relay. Completely solid state and self-contained, these proximity switches have both AC and DC outputs. Factory Mutual approved: Class I, Division 2, Groups A, B, C and D and are suitable for Class II, Group G hazardous locations. All Telemecanique proximity switches are FM approved for this non-incendive rating. Non-incendive equipment is deŢned as unable to release sufŢcient electrical or thermal energy under normal operating conditions to cause ignition of speciŢc hazardous materials. Non-incendive equipment can be used without additional precautions in Division II hazardous locations where the hazardous materials can be present only in case of accidental rupture or breakdown of the enclosure containing them. DeŢnitions Class I Locations: Are those in which ţammable gases or vapors are or may be present in the air in quantities sufŢcient to produce explosive or ignitable mixtures. Class II Locations: Are those which are hazardous due to the presence of combustible dust. Class III Locations: Are those which are hazardous due to the presence of easily ignitable Ţbers of ţyings, but in which such Ţbers or ţyings are not likely to be in suspension in the air in quantities to produce ignitable mixtures. Division I Locations in which hazardous concentrations in the air exist continuously, intermittently, or periodically under normal operating conditions. Division II Locations in which hazardous concentrations are handled, processed, or used but are normally within closed containers or closed systems from which they can escape only in case of accidental rupture or breakdown. Group A Atmospheres containing acetylene. Group B Atmospheres containing hydrogen, or gasses or vapors of equivalent hazard, such as manufactured gas. Group C Atmospheres containing ethyl-ether vapors, ethylene, or cyclo propane. Group D Atmospheres containing gasoline, hexane, naptha, benzine, butane, alcohol, acetone, benzol, lacquer solvent vapors, or natural gas. Group E Atmospheres containing metal dust, including aluminum, magnesium, and their commercial alloys, and other metals of similarly hazardous characteristics. Group F Atmospheres containing carbon black, coal or cake dust. Group G Atmospheres containing ţour, starch, or grain dust. Excerpt from the National Electrical Code Equipment and associated wiring approved as intrinsically safe shall be permitted in any hazardous (classiŢed) location for which it is approved, and the provisions of Articles 500 through 517 shall not be considered applicable to such installation. Means shall be provided to prevent the passage of gasses and vapors. Intrinsically safe equipment and wiring shall not be capable of releasing sufŢcient electrical or thermal energy under normal or abnormal conditions to cause ignition of a speciŢc hazardous atmospheric mixture in its most easily ignitable concentration. Abnormal conditions shall include accidental damage to any Ţeld installed wiring, failure of electrical components, application of over- voltage, adjustment and maintenance operations, and other similar conditions. 2 © 1998 Square D All Rights Reserved 1/98 Intrinsically Safe Barrier Relays NY2 – Relays For Hazardous Locations Ordering Information NY2 A•1 Single Channel, Dual Relay Output A single channel relay that will accept either a NAMUR proximity sensor or a dry contact switch input. Two SPDT outut relays are ganged to provide two NO and two NC contacts. The housing is glass-reinforced nylon for back plate or DIN rail mounting. Terminals have captive screws with self-lifting clamps. Each relay has an independent LED function indication. Power Supply Catalog Number 24/48 Vac NY2 A11 110/220 Vac NY2 A21 NY2 B•1 Dual Channel, Relay Output With dual channel relay. Each channel will accept either a NAMUR proximity sensor or a hard contact switch input. Each channel has independent SPDT output relays. The housing is glass-reinforced nylon for back plate or DIN rail mounting. Terminals have captive screws with self-lifting clamps. Each relay has an independent LED function indication. Power Supply Catalog Number 24/48 Vac NY2 B11 110/220 Vac NY2 B21 120/240 Vac NY2 B31 NY2 F•1 Dual Channel, Transistor Output Transistor outputs are suitable for DC signal switching or for fast response time (speed, motion, counting, etc.). Each channel will accept either a NAMUR proximity sensor or a hard contact switch input. Each channel has an independent transistor output. The housing is glass reinforced nylon for back plate or DIN rail mounting. Terminals have captive screws with self-lifting clamps. Each output transistor has an independent LED function indication. Power Supply Catalog Number 24/48 Vac NY2 F11 110/220 Vac NY2 F21 120/240 Vac NY2 F31 NY2 K10 DC/AC Converter For Battery Operation A DC to AC converter that accepts 24 Vdc or 48 Vdc and provides a selectable output voltage supply of 24 Vac or 48 Vac. The housing is glass-reinforced nylon for back plate or DIN rail mounting. Terminals have captive screws with self-lifting clamps. The converter can supply three or four NY2 ••11 relays from a DC power supply (battery). Power Supply Catalog Number 24/48 Vac NY2 K10 3 © 1998 Square D All Rights Reserved 1/98 Intrisically Safe Barrier Relays NY2 – Relays For Hazardous Locations Specifications General SpeciŢcations 24/48 Vac, 110/220 Vac, 120/240 Vac (+10%/-15%), 50/60 Hz Supply voltage (for NY2 K10: 24 or 48 Vdc – 15%) Consumption 4 VA Resistance to shock Greater than 25 G Resistance to vibration 0-25 Hz, 2 mm amplitude Enclosure rating IP20, NEMA 1 (CENELEC) Operating temperature -4 to 122 °F (-25 to +50 °C) Approvals CENELEC 3: EN 50014 and 50020; NAMUR and DIN 19234 LC1F No. 80223X Factory Mutual approved, CSA certiŢed Input parameters (conforms to NAMUR) Supply voltage Max 7.7 to 9 Vdc (provided by the IS relay) Internal resistance 100 W, – 5% Maximum current 10 mA Response time 5 ms with relay output, 0.2 ms with transistor output Maximum line resistance 50 W with a NAMUR sensor Maximum line capacitance 0.8 mF Maximum line inductance 18 mH Output parameters Relays Mechanical life 10 million cycles Closing: 10 ms Response time Opening: 30 ms I max. (AC): 5 A Power max (AC): 100 VA @ 110 to 240 Vac 50 VA @ 24 to 48 Vac V max (AC): 250 Vac Contact ratings Frequency (max): 10 Hz I max (DC): 0.4 A (L/R < 40 ms) Power max (DC): 24 W V max (DC): 110 Vdc Transistors Controlled by opto-isolator and protected against overvoltage and reverse polarity. Closing: 0.3 ms Response time Opening: 0.7 ms I max: 100 mA (L/R =0) Output ratings V max: 30 Vdc Frequency (max) 500 Hz NY2 K10 load @ 24 Vdc Three NY2 ••1 relays @ 48 Vdc; four NY2 ••1 relays Factory Mutual approved: Intrinsically safe for Class I and Class II, Division I, Groups A, B, C, D, E, F and G. Report 1M4A1.AX. CSA certiŢed LR 15996 Class 3218 06. 4 © 1998 Square D All Rights Reserved 1/98 110 24 Intrinsically Safe Barrier Relays NY2 – Relays For Hazardous Locations Dimensions, Wiring Recommendations Approximate Dimensions Wiring recommendations Mounted onto backplate Inductive and capacitive effects Dimensions in inches (millimeters) In order to minimize any inductive effects from adjacent cabling, it is recommended that individual IS circuits be run out and back by a pair of conductors contained within the same sheath. Check cable inductance and capacitance for long cable runs against NY2 input line parameters to determine maximum cable length. For long cable runs, twisted pairs are recommended. 1.37 to 1.47 4.17 == (35 to 37.5) Terminals (106) 4.33 1.97 (110) Where the same set of terminal blocks are used to connect (50) both IS and non IS circuits, a minimum spacing of 2 in. (50 mm) should be observed between the different circuits, or if possible, a grounded screen should be mounted between them. Mounting on 35 mm DIN3 track In a hazardous area such an arrangement would require a explosion proof junction box, due to the presence of non IS cabling. Separate terminal blocks are often used. Junction boxes Where a junction box is being used only for IS cabling, there is no need to use a explosion proof type, and any type of standard box can be used provided that it has a minimum 4.45 1.97 degree of protection. (113) (50) Interconnection between circuits being fed from the same IS relay The use of a common link between two IS circuits on the same relay is not allowed. Mounted onto asymmetrical No interconnection between two or more IS relays or channels is allowed due to the adverse effects on the input DIN rail (DZ5 MB) using parameters of the relay, and the fact that the cumulative adaptor RHZ 66 effects of voltage and current would increase the risks of sparking above those of the normal IS levels. Series/Parallel Combinations are allowed for mechanical/dry contacts only. Grounding Do not ground devices in the hazardous areas at the same 4.92 1.97 ground as the ones in non-hazardous areas. Floating or (125) (50) separate grounds are recommended. Line voltage selector Plug in the fusible holder with the desired line voltage at the tip of the arrow 0.25A 0.63A 5 © 1998 Square D All Rights Reserved 1/98 48 2.95 2.95 (75) 2.95 (75) (75) 220 = 2.36 to 2.46 = 1.57 1.37 (60 to 62.5) (40) (35) Intrisically Safe Barrier Relays NY2 – Relays For Hazardous Locations Wiring Diagrams Switch Target Target Switch + – + – B11 B12 B13 B14 B21 B22 B23 B24 B11 B12 B13 B14 B21 B22 B23 B24 NY2 A•1 NY2 A•1 Both relays are Both relays are energized when energized when target is sensed target is removed or switch is opened. or switch is closed. 18 16 15 28 26 25 A1 A2 18 16 15 28 26 25 A1 A2 L1 L2 L1 L2 Switch Switch Target Switch Target Target Switch Target + + – + – + – – NY2 B•1 NY2 B•1 B11 B12 B13 B14 B21 B22 B23 B24 B11 B12 B13 B14 B21 B22 B23 B24 Relays are Relays are independently independently energized when energized when target is target is sensed or switch is removed or switch is opened for closed for each each channel. channel. 18 16 15 28 26 25 A1 A2 18 16 15 28 26 25 A1 A2 L1 L2 L1 L2 Switch Switch Target Switch Target Switch Target Target The output transistors can be wired either in the sinking or sourcing mode as illustrated below – + – + + – + – +VCC NY2 F•1 NY2 F•1 B11 B12 B13 B14 B21 B22 B23 B24 B11 B12 B13 B14 B21 B22 B23 B24 +VCC Transistors Transistors 18 LOAD conduct conduct independently independently 18 when target is when target 16 sensed or is removed or 120 VAC 120 VAC 18 16 15 28 26 25 A1 A2 switch is opened 18 16 15 28 26 25 A1 A2 switch is closed LOAD 16 for each channel for each channel –VCC L1 L2 L1 L2 –VCC Sinking mode Sourcing mode Battery operated system Switches d‡ 50mm B11 B12 B13 B14 B21 B22 B23 B24 B11 B12 B13 B14 B21 B22 B23 B24 B11 B12 B13 B14 B21 B22 B23 B24 24/48 V Convertisseur NY2 11 NY2 11 NY2 11 NY2 K10 LC1 E No. 03 0004X [EE] LC1 E No. 03 0004X [EE] LC1 E No. 03 0004X [EE] LC1 E No. 03 0004X [EE] LC1 E No. 03 0004X [EE] LC1 E No. 03 0004X [EE] 24/48 V 0.8 A off 200V – 5A – 100VA 200V – 5A – 100VA 50-60Hz 200V – 5A – 100VA 50-60Hz 50-60Hz 18 16 15 28 26 25 A1 A2 18 16 15 28 26 25 A1 A2 S1 S1 S1 S1 S2 S2 S2 S2 18 16 15 28 26 25 A1 A2 24/48 VDC 6 © 1998 Square D All Rights Reserved 1/98 BARRIER RELAY BARRIER RELAY Intrinsically Safe Barrier Relays Class 8501 – Type TO General Information Example 2 General NONHAZARDOUS LOCATION HAZARDOUS LOCATION The Class 8501 Type TO barrier relays must be installed in a non- VAPOR PROOF SEAL JUMPER hazardous location. However, intrinsically safe equipment and the WIRE NEGATIVE LEAD associated wiring can be installed in the hazardous location for PROXIMITY SWITCH 1 7 (FM ENTITY APPROVED) which the devices are approved, without the need for an explosion- POSITIVE LEAD 8 2 RELAY proof housing or similar protection. OUTPUT TERMINALS { CASE GROUND WIRE 9 (IF ANY) 3 Diagram of a Typical Intrinsically Safe Installation 10 4 NONHAZARDOUS LOCATION HAZARDOUS LOCATION INTRINSICALLY SAFE POWER 11 5 PILOT LIGHTS SOURCE 12 (SUCH AS SQUARE D CLASS 9001 6 INTRINSICALLY SAFE CIRCUIT VAPOR PROOF SEAL TYPE KP44 INTRINSICALLY SAFE PILOT LIGHTS) ONLY DEVICES THAT HAVE FM ENTITY 120V 60 Hz } TO 41 APPROVAL MAY BE USED 110V 50 Hz 240V 60 Hz PHYSICAL BARRIER TO 43 } 220V 50 Hz Connection: HAZARDOUS AREA EQUIPMENT NONHAZARDOUS LOCATION SUCH AS STANDARD PUSH EQUIPMENT SUCH AS CONTACT- The maximum voltage and current rating of each device in the hazardous BUTTONS, LIMIT SWITCHES, TORS, RELAYS, MOTOR CON- INTRINSICALLY SAFE PILOT TROL CENTERS ETC. locations which are connected to the Class 8501 Type TO41/TO43 barrier LIGHTS ETC. THE BARRIER RELAY MUST relay must be greater than or equal to the maximum open circuit voltage (V ) OC THIS EQUIPMENT DOES NOT BE MOUNTED HERE. NEED TO BE EXPLOSION PROOF. and maximum short circuit current (I ) that the relay can deliver. SC The sum of the total capacitance and total inductance of all the intrinsically safe devices connected to the relay, including Ţeld wiring, must not exceed Terminals 1 through 6 of the barrier relay are the intrinsically safe the values shown in Table 1. terminals. The input devices and intrinsically safe pilot lights that are Table 1 located in the hazardous location are wired to these terminals. The Total inductance and capacitance which may be connected to the intrinsically safe maximum voltage available to these terminals is 28Vdc. This is terminals. called the maximum open circuit voltage (V ). The maximum OC Max. Max. Groups current available to these terminals is 115mA. This is called the C uF L mH a a maximum short circuit current (I ). SC 0.12 2.7 A, B 0.36 11.0 C, E If the barrier relay is to be controlled by a 2-wire pilot device, such as a proximity switch or limit switch, the switch is then wired to terminals 0.96 22.0 D, G 2 and 3 and a jumper is placed between terminals 1 and 2. C Maximum allowable connected capacitance. a L Maximum allowable connected inductance. a Only devices that have been approved as intrinsically safe and meet the requirements of Factory Mutual's entity approval should be connected to this relay. Refer to the section on “Connection.” Connection Diagram 123456 OFF Intrinsically safe equipment is suitable only for the speciŢc ON hazardous location classes, divisions and groups for which it has OFF ON been designed and investigated. The relay can be used with such devices that are installed in hazardous locations designated as Intrinsically Safe Terminals Class I, Division 1 or 2, Groups A, B, C, D; Class II, Division 1 or 2, Groups E & G; and Class III locations dependent upon the SUPPLY hazardous location rating which must be marked on these devices. VOLTAGE Example 1 7 89 10 11 12 NONHAZARDOUS LOCATION HAZARDOUS LOCATION Non-Hazardous Location Terminals VAPOR PROOF SEAL MECHANICAL - TYPE PUSH BUTTON SWITCHES 1 7 HAVING NO ENERGY It is very important that terminal 6 be properly grounded, before power is 2 8 STORAGE CAPABILITIES RELAY (SUCH AS SQUARE D CLASS 9001 applied. OUTPUT TYPE K OR D SWITCHES) TERMINALS { 9 3 Terminals 7 through 12 of the barrier relay are the non-hazardous location 10 4 INTRINSICALLY SAFE PILOT LIGHTS terminals. Terminals 7-8 and 9-10 are hard contact relay outputs N.O. and (SUCH AS SQUARE D CLASS 9001 POWER TYPE KP44 INTRINSICALLY 11 5 N.C., respectively. These contacts change state when the barrier relay input SAFE PILOT LIGHTS) SOURCE 12 6 is activated. This is indicated by the illumination of an LED located on the front ONLY DEVICES THAT HAVE FM ENTITY face of the barrier relay. This LED is labeled “Relay Output Status.” APPROVAL MAY BE USED 120V 60 Hz } TO41 110V 50 Hz Terminals 11 - 12 are connected to the supply voltage (120V - 60Hz/110V - 240V 60 Hz PHYSICAL BARRIER } TO43 220V 50 Hz 50Hz for the 8501 TO41 and 240V - 60Hz/220V - 50Hz for the 8501 TO43). 7 © 1998 Square D All Rights Reserved 1/98 Intrisically Safe Barrier Relays Class 8501 – Type TO Order Information, Application Data and Approximate Dimensions Equipment that is intrinsically safe is suitable for use in speciŢc hazardous locations because of the reduced electrical and thermal energy of the equipment. The Class 8501 Type TO barrier relays are Factory Mutual approved for use with approved equipment mounted in Class I, Class II and Class III locations (see page 7). See page 2 for a summary of classiŢcation chart. The barrier relay is used in applications where a load (motor starter, control relay, etc.) in a nonhazardous location must be controlled by input devices or sensors in a hazardous area. With the barrier relay interposed between the input devices and the load, the input devices will not need to be the explosion-proof type. An example application would be a combination starter in a non-hazardous area controlled by push buttons located in the hazardous area. • Provides an alternative to explosion- • Factory Mutual approved. Report 0J6A4.AX. proof enclosures • Ideal for spray paint lines, petrochemical • Reduces equipment costs plants, petroleum reŢneries, and grain elevator arsenals • Provides easy maintenance • Saves on wiring Mounting Track Barrier Relay Supply Voltage Type Voltage Class 8501 Description Type 120V/60 Hz TO41 V20 110V/50 Hz 9" long for 4 relays XM4 18" long for 8 relays XM8 240V/60 Hz 27" long for 12 relays XM12 TO43 V24 220V/50 Hz The Type TO Barrier Relay mounts on Class 8501 Type XM mounting track. Output Contacts: Approximate Dimensions 1 N.O., 1 N.C. 2.18 5 Amperes resistive @ 30 Vdc or 120 Vac (55) 1/6 HP @ 120 Vac 4.10 1.09 (104) (28) Nominal Output Voltage: 24 Vdc Maximum Open Circuit Voltage (V ): 28 Vdc OC Maximum Short Circuit Current (I ): 115 mA SC Minimum Trip Current at 25°C: 52 mA if the internal 3.50 3.12 relay is not energized; 40 mA if the internal relay is ener- (79) (89) 0.41 gized. DIA (10) Operating Information: 0.09 0.19 2 ea. If the relay output protection circuit is triggered due to an R (5) (2) overload condition, input power to the relay (terminal 11 USE 8-32 UNC-2A MOUNTING SCREW and 12) must be interrupted for a minimum of six Dimensions are in inches (millimeters) seconds to reset. Burden: 3 VA nominal. Wire Size: Terminals will accept one or two #22 to #12 AWG wires. Terminals should be tightened to 6 to 9 in-lb. Wires must be sized in accordance with the require- How To Order: ments of the National Electrical Code. To Order Catalog Number Operating Temperature Range: -20 to +60°C (-4 to Specify: 140°F) k Class Number Class Type Voltage Code k Type Number The relay is NOT repairable. Substitution of components k Voltage Code 8501 TO41 V20 may impair the intrinsic safety of the device. Square D and are registered trademarks of Square D Company. Square D Company FM is a registered trademark of Factory Mutual. 8001 Hwy 64 East CSA is a registered trademark of Canadian Standard Association. Knightdale, NC 27545 8 © 1998 Square D All Rights Reserved 1/98 (919) 266-3671 Catalog No. 8501CT9702 January 1998 © 1998 Square D All Rights Reserved.