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