ATEX Instructions MODEL XRB1 SMARTSafeTM 8 9 0 1 E . P L E A S A N T VA L L E Y R O A D • I N D E P E N D E N C E , O H I O 4 4 1 3 1 - 5 5 0 8 T E L E P H O N E : ( 1 ) 2 1 6 - 6 4 2 - 1 2 3 0 • FA X : ( 1 ) 2 1 6 - 6 4 2 - 6 0 3 7 E - M A I L : t a c h s @ n i d e c - a v t r o n . c o m • W E B : w w w. a v t r o n e n c o d e r s . c o m DESCRIPTION The Avtron Model XRB1 (part number B35134) isolator is designed to limit voltage and current to a potentially hazardous area installation of an AvtronSMARTSafe™ encoder. CAUTION The XRB1 isolator is designed only for use with an Avtron SMARTSafe™ encoder model XR_ _ _ _ line driver option 5. Use with other brands of encoder or non-listed Avtron encoders is not suitable for use in hazardous areas and will result in an unsafe condition which may result in property damage, injury, or even death. The XRB1 has been evaluated to be compliant with IEC60079-0:2007, IEC60079-11:2011, EN60079-0:2009, EN60079-11:2012, BSEN 61000-6-4:2007 and BSEN61000-6-2:2005 (Certificates of conformity: TRAC12ATEX0002X, TRAC12ATEX 0003X, IECEx TRC 12.0009X, and IECEx TRC12.0001X.) THE XRB1 IS CERTIFIED FOR USE IN: Group II, Category 2 (ATEX Zone 1), Gas Group IIC potentially explosive atmospheres when marked CE 0539 EX II 2 GD, Ex ib IIC T4 Gb -40°C < Tamb < 80°C and used with an Avtron isolator marked CE 0539 EX [II 2 GD] [Ex ib IIC Gb] -40°C<Tamb<80°C. Group II, Category 2 (ATEX Zone 21), Dust Group IIIC potentially explosive atmospheres when marked CE 0539 EX II 2 GD, Ex ib IIIC T200°C Db -40°C<Tamb<80°C and used with an Avtron isolator marked CE 0539 EX [II 2 GD] [Ex ib IIIC Db] -40°C<Tamb<80°C . The isolator must be installed in a safe area and is marked: CE 0539 [II 2 GD] [Ex ib IIC Gb] -40°C < Tamb <80°C [Ex ib IIC Db] -40°C < Tamb <80°C INSTALLATION Equipment Group II, Category 2 (Zone 1), Gas Group IIC, Dust group IIIC (Zone 21): Available as a system only including XR_ _ _ _ Encoder with line driver option 5 and an Avtron Isolator module XRB1 (P/N B35134). INTRINSIC SAFETY ISOLATOR FOR HAZARDOUS APPLICATIONS NOTE Isolators, encoders and cable must be selected and installed in accordance with the latest edition of IEC/EN60079-14 and ICE/EN60079-25. Cable characteristics must comply with IEC/EN60079-14 and IEC/EN60079-25 and Zone 1 and Zone 21 applications total system capacitance between the isolator and encoder (including cable) must be less than Co-Ci. Total system inductance between the isolator and encoder must be less than Lo-Li. INSTALLATION HARDWARE Installation hardware required is attached to each assembly. Equipment needed for installation Supplied: XRB1 Isolator DIN rail clip Not Supplied: Screwdriver DIN rail WARNING Installation should be performed by qualified personnel. Safety precautions must be taken to ensure all sources of power are removed during installation. WIRING INSTRUCTIONS See wiring diagrams (Figure 2) for interconnection information and cable types. Interconnection cables specified in the wire selection charts are based on typical applications cable characteristics must comply with ICE/EN 60079-14 and IEC EN600079-25. Cable must be installed in accordance with the latest edition of IEC/EN 60079-14 and IEC 600079-25 physical properties of cable such as abrasion, temperature, tensile strength, etc are dictated by specified applications. General electrical required are 16 or 18 AWG stranded copper twisted pairs with either an overall shield, individually shielded pairs or both. Encoder parameters are: Ui (input voltage) = 7.14VDC max Ii (fault current) = 420mA max Ci (internal capacitance) = 11.9uF max Li (internal inductance) = )mH max CAUTION SMARTSafe™ encoders include a local ground lug for customer convenience and encoder frame grounding if required to meet local electric code requirements or site operator protection standards. This is NOT the required XRB1 intrinsic safety ground connection required for hazard protection against ignition of explosive atmospheres! CAUTION The XRB1 isolator requires an intrinsic safety ground to provide hazard protection. Failure to connect this ground, or providing an inadequate safety ground path can result in an spark/ignition hazard which can result in property damage, injury, or even death. The isolator XRB1 can be supplied remotely as a separate module for location in a safe area or in an explosion proof box on a short flexible cable tethered to the encoder. For bidirectional operation of the encoder, proper phasing of the two output channels is important. For all Avtron SMARTSafe encoder models, see wiring labels for phasing information. System parameter are: Um=250V Uo (open circuit voltage) = 7.14VDC max Io (short circuit current) = 420mA max Co (system capacitance) = 13.5uF max Lo ( system inductance) = 0.15mH max XRB1 1 CORRECTIVE ACTION FOR PHASE REVERSAL 1) Remove Power. 2) Exchange wires on cable, either at XRB1 output cable end or at speed controller end (but not both).(see wiring diagram) Exchange either A with A in the phase A pair OR B with B in the phase B pair but NOT both. 3) Apply power and verify encoder feedback is correct. If the controller indicates encoder fault, but the encoder LED shows GREEN, then check the wiring between the XRB1 and the encoder. If the wiring appears correct and in good shape, check the wiring between the XRB1 and the control system. If all wires seem intact, test the wiring by replacing the encoder. If the new encoder shows GREEN, and the drive still shows encoder loss/tach fault, then the wiring is faulty and should be repaired or replaced. Interconnecting cables specified in the WIRE SELECTION CHART in Figure 2 are based on typical applications. Refer to the system drawing for specific cable requirements where applicable. If the encoder LED indicates a fault (RED): Check the encoder manual for the SMARTSafe encoder. Physical properties of cable such as abrasion, temperature, tensile strength, solvents, etc., are dictated by the specific application. See WIRE SELECTION CHART in Figure 6 for some suggested cables. All signals (A, A, B, B) should show square wave outputs if the encoder shaft is turning. Z and Z can only be seen typically by using the “capture” mode of the scope. MAINTENANCE GENERAL This section describes routine maintenance for the Avtron XRB1 Isolator. For support, contact Avtron’s field service department at 216-642-1230. For emergency after hours service contact us at: 216-641-8317. The XRB1 Isolator includes a non-user-replaceable fusable element. If the SMARTSafe™ encoder and XRB1 isolator are properly wired and the LED does not illuminate on the encoder, try replacing the XRB1 isolator. If the XRB1 isolator is damaged, do not attempt to service it or replace the fusable elements. Doing so can create a hazardous condition. Replace the damaged XRB1. TROUBLESHOOTING: An oscilloscope can also be used to verify proper output of the SMARTSafe encoder at the input “Safe Area” terminals of the XRB1 isolator and at the drive/controller cabinet. If the A, A, or B, B outputs show large variations in the signals at steady speed (jitter or “accordion effect”, see figure 1), check encoder rotor position for modular encoder styles such as XR56, XR67, XR85, XR115, XR125, XR850. If the rotor position is correct or the encoder does not have a separately mounted rotor, the motor or shaft may be highly magnetized. Replace any magnetized material nearby with nonmagnetic material (aluminum, stainless) (shafts, etc). For many motors Avtron offers non-magnetic stub shafts. If variations persist, consider replacing the sensors or encoder with super-shielded models, option -004 for XR4F, XR45, XR47, XR125, XR485, XR685, and XR850. For XR56, XR67, XR85, and XR115, super shielding is option -005. RENEWAL AND SPARE PARTS 316374 Safe area terminal strips (black), 2 per XRB1 316373 Hazardous area terminal strips (blue), 2 per XRB1 B35303 DIN rail mount CAUTION Be certain no atmospheric hazard exists during troubleshooting of XRB1. If the drive indicates a loss of encoder/tach fault and the SMARTSafe encoder fault-check LED is not illuminated, check the encoder power supply. If power is present, check polarity. First check polarity to the XRB1; one indicator of reversed power supply to the XRB1 is that all outputs of the XRB1 will be high (~10-11V) at the same time. NOTE: the intrinsic safety ground terminal (top of the XRB1) is non-removable and non-serviceable. It this terminal is damaged or unusable, replace the damaged XRB1. If the supply voltage to the XRB1 has correct polarity, check polarity to the encoder. Likewise, if polarity from the XRB1 to the encoder is reversed, all outputs from the encoder to the XRB1 inputs will be high (~4.5-7V) at the same time. XRB1“Safe Area” terminals: nominal signal output voltage (A, A, B, B, Z, Z) for the XRB1 is (10-11)V. Outputs may be at ~0V or ~10-11V, depending on the encoder line state (high or low). XRB1 “Hazardous Area” terminals: nominal supply voltage (marked +,-) from the XRB1 to the encoder is ~6.8V, but may be 5-7V depending on cable length between the XRB1 and the encoder. The minimum power supply voltage as measured at the SMARTSafe encoder should be >4.5V. This will also result in a minimum ~4.5V differential signal as measured on the input (A, A, B, B, Z, Z)“Hazardous Area” terminals of the XRB1. FIGURE 1 PHASE A PHASE B Check current draw. Disconnect the connection to the encoder at the encoder itself, but leave the wiring complete to the encoder connector. Insert a DC ammeter between the controller and the XRB1 at the controller panel. The XRB1 will draw approximately 100-160mA without an encoder connected; if current draw is far in excess of this amount with the encoder disconnected, check the input and output wiring for shorts to dc power line or ground. If the wiring checks out ok, replace the XRB1 and check current draw again. XRB1 VARIATION > ± 15% 2 SPECIFICATIONS ELECTRICAL A. Operating Power (Vin) 1.Volts............................. 12-24 VDC in 2.Current A. Remote XRB1......... 150mA nominal (incl. encoder w/500’ cable @ 1024 PPR, 1800 RPM) B. Maximum................ 440mA (short circuit) B. Output Format – – 1.2O// & Comp................. A,A , B,B (differential line driver) – 2. Marker:........................ 1/Rev Z, Z C.Signal Type...................... Incremental, Square Wave D.Frequency Range............ 0 to 165,000 Hz E. Line Driver Specs:........... See table Electrical Specifications Input Voltage Nom Output Voltage Line Driver MECHANICAL A. Weight:............................ 1.1 lbs. [ 0.5 kg.] - - 7.14V Li - 440mA Pi - 0.4W Ci - 11.9UF Li - 0mH 7.14V - Io 440mA - Po 0.4W - Lo 1.5mH Co 13.5uF Lo/Ro - 5 VDC IXDF604 7272 ohms mA Maximum Average Current 350 120 mA Voh Typ 10.6 VIN-1 VDC Vol Typ 0.4 0.5 VDC 1000’ 500’ feet Reverse Voltage yes yes Short Circuit yes yes Transient yes yes Protection Zone 1 Table of entity parameters XRB1 (5-7 to Encoder) 10.6 Output Signals 13 Encoder Uo VDC 1500 For Level 1 Remote Protection: XRB1 Ui 5-7 3 PART NUMBER ORDERING INFORMATION 250V 12-24 3000 Cabinet/Explosion Proof Box Mounting Only Temperature:.......................-40 to 80°C, 0-100% non-condensing humidity Isolator Units Maximum Peak Current ENVIRONMENTAL Um SMARTSafe Encoder Output Resistance Typ Cable Drive Capacity Parameter Isolator XRB1 3 WIRING DIAGRAMS ZONE 1 HAZARDOUS AREA “LOCAL PROTECTION’ SAFE AREA 1'(.3M) to 5'(1.5M) Cable Tether LINE DRIVER OPTION 5 CONNECTOR OPTION 5 OR 6 12-24 Volts In + AA+ BB+ ZZ+ K1- 1K1+ 1+ K2- 2K2+ 2+ K0- 0K0+ 0+ - GND 0V + Ub+ +E 12-24 Volts Out gnd gnd Typical Cable 1000'(300M)max Intrinsic Safety Gnd 18AWG, Individually Shielded Twisted Pair + Overall Shield Rockbestos EXANE 125 Type P- P/N: 4TSP18 AWG ZONE 1 HAZARDOUS AREA “REMOTE PROTECTION’ + A A B B Z Z ISOLATOR P/N B35134 SAFE AREA A A B B Z Z 12-24 Volts In + 5-7 Volts Out AA+ BB+ ZZ+ K1- 1K1+ 1+ K2- 2K2+ 2+ K0- 0K0+ 0+ - GND 0V + Ub+ +E Customer Equipment 2 Phase Differential ENCODER A A B B Z Z 5-7 Volts Out Customer Equipment 2 Phase Differential A A B B Z Z ISOLATOR P/N B35134 Ex Box + 12-24 Volts Out gnd gnd Typical Cable 500'(150M)max ENCODER 18AWG, 4 Twisted Pair + Overall Shield Belden P/N 9554 or Alpha P/N 2244C Typ Intrinsic Safety Gnd See Attached for Connector Option Pin Outs FIGURE 2 NOTE: Avtron standard 3 year warranty applies. Copies available upon request. Specifications subject to change without notice. Top view of XRB! (P/N B35134) Isolator Module FIGURE 3 XRB1 4 Ex ENCLOSURE ASSEMBLY WITH MOUNTING BRACKET [139.0] [97.0] [94.0] TO ENCODER 3’ (.9M) TO 5’ [1.5M] CABLE LENGTH CUSTOMER WIRING 3/4” NPT OR SIZE 25 ATEX GLAND [27.0] [8.0] [103.0] OPTIONAL RT ANGLE MTG BRACKET INCLUDED [9.0] [185.0] [23.0] [70.0] [65.0] [20.0] [20.0] [14.0] [50.0] [157.0] [104.0] [153.0] XRB1 5 OUTLINE DIMENSIONS AND OPTION DETAILS FIGURE 10 For additional wiring options see Figure 2 INTRINSIC SAFETY GROUND 3.88 [99.0] 1.12 [28.5] 0.45 [12.0] 0.90 [23.0] 5.84 6.07 [149.0] [154.0] 0.24 [0.60] 0.34 [0.86] 1.77 [45.0] These instructions have been reviewed and the product evaluated as suitable for our application. Company Name Authorized Company Representative Title Date SMARTSafe™ is a trademark of Avtron Industrial Automation, Inc. Features and specifications subject to change without notice. Avtron standard warranty applies. All dimensions are in inches (mm). 8901 E. PLEASANT VALLEY RD., INDEPENDENCE, OH 44131, U.S.A. (1) 216-642-1230 • FAX (1) 216-642-6037 • www.avtronencoders.com XRB1 6 REV: 03/25/13