2.

Intrinsic Safety Rules for Fieldbus Installations

J. BERGE

Intrinsically safe installation becomes simpler and more economical if the correct equipment is used:

Isolated safety barriers

Safety barriers with built-in repeaters
Safety barriers with built-in terminators
Devices with low power consumption
A typical entity concept barrier for fieldbus such as
Smar SB302 costs U.S.$400
A typical FISCO model barrier for fieldbus such as
Smar DF47 costs U.S.$450
A typical repeater for fieldbus such as Smar RP302
costs U.S.$300

Foundation Fieldbus and PROFIBUS PA are based on the

IEC 61158-2 standard that provides communication and
power on the same pair of wires. Essentially, there is not a
great difference between a regular fieldbus network and an
intrinsically safe network. Basic topology remains the same
with terminators in each end (see Section 4.2). For an intrinsically safe installation, a safety barrier is used in place of
the regular power supply impedance. Other differences include
fewer devices per wire. When this wire is run in a hazardous
area, intrinsic safety is one of the better protection methods.
Fieldbus was specially developed to enable it to be used in
intrinsically safe systems. For example, field instruments
can be designed in such a way that they do not inject power
onto the bus, which is one of the requirements for intrinsic
safety.
Installation of instruments is made easy by fieldbus.
Foundation Fieldbus H1 was specially created to enable reuse
of existing cables, and therefore it does not have as many
special requirements for knowledge and tools as do other
networks. Make sure to follow local regulations and carefully
read the manuals and follow the manufacturers instructions
before installing any device.

not changed. In an intrinsically safe system power is only

supplied from a single source, through the safety barrier. All
the field instruments are passive in the sense that they only
consume power (Figure 2.2a).
Fieldbus devices operate on a voltage anywhere between
9 and 32 VDC from the bus. Because the concept of intrinsic
safety is to limit power, the bus usually operates at the lower
end of this range. Separately powered devices are also possible, but even so these devices are forced to draw at least
10 mA quiescent current from the network to be able to
manipulate the current during communication without injecting power on the bus. The fieldbus connection is electrically
almost identical for all devices including analog and discrete
performing input as well as output functions. Therefore, a
fieldbus-based system requires only a single barrier type.
The main distinguishing difference between field devices
from different suppliers is their power consumption. It is
important to select devices with low power consumption to
enable as many devices as possible to be connected to each
barrier because the power available to an intrinsically safe
bus is limited. The barrier may be a zener barrier or an
intrinsically safe galvanic isolator. Intrinsically safe fieldbus
devices are current sinking and do not provide power to the
network. The main limiting factor to the number of devices

Host

Linking
Device

Safe Side
Hazardous Side

INTRINSIC SAFETY
The concept of intrinsic safety is the same for fieldbus as it is
for conventional installation, i.e., the basic rules for limiting
the energy to a level below what is required for ignition are

FIG. 2.2a
The safety barrier limits the amount of energy on the network in
the hazardous area.

161
2002 by Bla G. Liptk

162

Designing a Safe Plant

on the intrinsically safe network segment is the power consumption pushing the limit well below 32 devices. However,
barriers may be multidropped and still result in 16 devices
per interface port, which is important to keep system cost
down. It is a good idea to look for the lowest possible device
power consumption because it minimizes the number of
barriers required and thereby reduces the system complexity
and cost.
The fieldbus network terminators at each end of the bus
contain a capacitor and, therefore, to be used in intrinsically
safe installations, must also be certified intrinsically safe.
Because power is scarce, the terminator should be totally
passive without current consumption in order not to reduce
cable length or device count. IEC 61158-2 barriers are different
from barriers for other kinds of networks. Therefore, make
sure to use the correct type of barrier.
For intrinsic safety design and installation, follow local
regulations and codes of practice and make sure to read the
respective user manuals. Connect only intrinsically safe certified devices in the hazardous area.
A basic rule of intrinsic safety is that there can only be a
single source of power; therefore, safety barriers cannot be
redundant, i.e., only one safety barrier can be connected to
each hazardous area segment. Typically, the barriers are
mounted in the safe area because it is much cheaper and simpler. Sometimes distance or other limitations force the barriers
to be mounted in the hazardous area, in which case flameproof
enclosures with flameproof seals are needed. When nonisolated safety barriers are used, special care should be taken
to follow the instructions for grounding in the product manual.
The traditional entity concept and the newer FISCO model are
two schemes for supplying intrinsically safe power to the network. FISCO provides more power thereby enabling more
devices and longer cable than the entity concept.

ENTITY CONCEPT
Matching devices and barrier have to be selected based on
the entity parameters for voltage, current, power, capacitance,
and inductance stated in the approval certificate for the components. It is necessary to compile the entity parameters of
all devices to match the barrier because several devices are
multidropped off a single barrier. Unlike FISCO, in the traditional entity concept the total cable capacitance and inductance for the hazardous side segment of the network must be
taken into account when designing because the cable capacitance and inductance are considered concentrated.
Barriers with linear output characteristics are used for the
entity concept (Figure 2.2b). The output power is approximately
1.2 W or some 60 mA at 11 VDC for Exia IIC. Only a few
devices can be connected to each linear barrier due to this current
limit. Similarly, the cable length is limited by the low voltage
output as only a small voltage drop can be accommodated.

2002 by Bla G. Liptk

Uo
U
9V

Io

FIG. 2.2b
Linear characteristics of entity concept barrier.

FIG. 2.2c
Isolated repeating entity concept barrier. (Courtesy of Smar.)

A field device can only handle a limited voltage, power,

and current. Similarly, the total amount of inductance and
capacitance allowed on the bus is limited. A barrier should
be selected on a worst-case basis, i.e., it must have a voltage,
current, and power output lower than what is permitted by
the lowest corresponding entity parameter in the field devices
(Figure 2.2c).
The total external capacitance and inductance of all the
devices connected to the safe side plus the network cable
must be within the limits of the barrier. The cable data sheet
is typically the best place to obtain the cable parameters. The
inductance value for the cable will very often exceed the
value allowed for the barrier. However, it is common to
compare the inductance/resistance (L/R) ratio allowed by the
barrier to that of the cable instead of the inductance value
itself. It is often found that the limiting factor for distance in
intrinsically safe installations based on the entity concept is
the cable capacitance. Cables without screen have a lower
capacitance than those with screen.
An easy way to evaluate the network segment is to make
a table of the entity parameters for all components on the
network segment (Table 2.2d).
The maximum allowed cable capacitance is the balance
after all the device capacitances have been subtracted from the
capacitance allowed by the barrier. The maximum allowed

2.2 Intrinsic Safety Rules for Fieldbus Installations

163

TABLE 2.2d
Entity Concept Example
Tag

Ui (Vmax), V

Ii (Imax), mA

Pi (Pmax), W

Li, H

Ci, nF

L /R, H/

Iq, mA

PT-456

24

250

1.5

12

LT-789

24

250

1.5

12

PCV-456

24

250

1.5

12

LCV-789

24

250

1.5

12

Terminator

24

250

1.5

Wire

Barrier requirement
Selected barrier

100

275

0
25

min

min

min

sum

sum

Uo (Voc)

Io (Isc)

Po (Pm)

Co (Ca)

Lo (La)

Lo/Ro (L /R)

24

250

1.5

120

307

25

48

21.4

200

1.1

154

300

30.7

60

cable distance should be calculated based on the maximum

allowed cable capacitance.
Example Entity parameters for typical devices and a cable
are inserted (see Table 2.2d). The cable in this example is
500 m long and has 200 nF/km capacitance and a 25 H/
L/R ratio, which are typical values.
The output voltage, current, and power allowed for the
devices in this example exceed the barrier output, the current
provided by the barrier is sufficient, and the capacitance allowed
by the barrier is also sufficient. Although the inductance allowed is too low, a typical barrier has a permissible L/R ratio of
30.7 H/, which can still safely be used for this application.
Based on the barrier and cable in the example above the
maximum cable length due to capacitance can be calculated
to 670 m by subtracting the device capacitance from the
barrier limit:
154 4 5
--------------------------- = 0.670
200

sum

cable parameters are within given limits. FISCO-type barriers

have no specified permitted capacitance or inductance for the
same reason.
FISCO barriers have an output characteristic that is trapezoidal (Figure 2.2e), typically providing 1.8 W of output
power for Exia IIC. This greater power in turn enables more
devices to be connected as compared to a traditional entity
barrier (Figure 2.2f).

Uo/U
9V

Io

2.2(1)
FIG. 2.2e
Trapezoidal characteristics of a FISCO barrier.

FAULT DISCONNECTION
Fault disconnection electronics (FDE) is a circuit on the bus
connection in the device that limits the current drawn from
the network in case of a device circuitry malfunction. This
prevents the entire network from being short-circuited by the
failure of the electronics in a single device.
FIELDBUS INTRINSICALLY SAFE CONCEPT
FISCO was developed by PTB (Physikalisch-Technische
Bundesanstalt) to simplify and maximize the utilization of
networking in hazardous areas. Unlike the entity concept, in
the FISCO model the cable capacitance and inductance are
not considered concentrated or unprotected as long as the

2002 by Bla G. Liptk

FIG. 2.2f
Isolated repeating FISCO barrier. (Courtesy of Smar.)

164

Designing a Safe Plant

TABLE 2.2g
FISCO Cable Restrictions

TABLE 2.2i
FISCO Example

15150 /km

R (loop)

(4.646 /1000 ft)

4001000 H/km

L
C

(120300 H/1000 ft)

80200 nF/km

(2460 nF/1000 ft)

Shield

Conductors
Ccc

Ccs

Ccc

Ccs

C = Ccc + Ccs/2

Ccs

Ui
(Vmax), V

Ii (Imax), mA

Pi (Pmax), W

Iq, mA

FT-012

24

250

12

TT-789

24

250

12

LT-456

24

250

12

Tag

PT-123

24

250

12

FCV-012

24

250

12

TCV-789

24

250

12

LCV-456

24

250

12

PCV-123

24

250

12

Terminator

24

250

min

min

min

sum

Uo (Voc)

Io (Isc)

Po (Pm)

Barrier
requirement

24

250

Selected
barrier

15

190

1.8

C = Ccc + Ccs

FIG. 2.2h
Computing equivalent capacitance of the cable.

Example The number of devices that can be connected to

a FISCO barrier with a 100 mA-output current capacity based
on a typical device power consumption of 12 mA is eight,
simply calculated as:

96
100

Host

100
--------- = 8
12

2.2(2)

The capacitance and inductance of FISCO certified

devices are negligible (less than 5 nF and 10 H, respectively). FISCO field devices are designed to tolerate the high
power from a FISCO barrier. To be compatible with a typical
FISCO barrier, the Pi (Pmax) of the device should be larger
than the typical 1.8 W provided by the barrier.
There is no need to make the analysis for the cable and
devices in the network for inductance and capacitance. Cables
with parameters within the ranges specified in Table 2.2g can
be used in FISCO installations for lengths up to 1 km with
a maximum spur length of 30 m.
The connection of the cable shield affects the effective
cable capacitance that should be calculated using the equations in Figure 2.2h. If the conductors are isolated from an
earthed shield, the capacitance is lower than if the shield is
connected to one of the signal conductors at the barrier.
It is necessary to select a barrier that has voltage, current,
and power output lower than what is permitted for the field
device with the worst-case parameter.
Example Parameters for eight typical devices are listed
Table 2.2i.
The worst-case field device is higher than the output
voltage, current, and power of the barrier in this example,
and the current provided is sufficient. Thus, the suggested
barrier can be used.

2002 by Bla G. Liptk

Linking
Device
Safe Side
Segment
Barrier

Hazardous
Area
Segment

Barrier

Hazardous
Area
Segment

Barrier

Hazardous
Area
Segment

Barrier

Hazardous
Area
Segment

FIG. 2.2j
Network formed by four intrinsically safe and one regular segment.

The maximum cable length is calculated based on voltage

drop as for a regular non-intrinsically safe installation (see
Section 4.2) because there is no cable capacitance or inductance limitation as long as the specified cable parameters are
followed.
For an intrinsically safe installation with eight devices
using a safety barrier with 13.8 V output, the maximum
distance is calculated as 1.1 km considering only the voltage
drop. However, other aspects set the limit for Exia IIC as

AUXILLIARY ROOM

FIELD

CABINET

MARSHALLING PANEL

JUNCTION BOX

INSTRUMENT

TAG
TAG

TAG

TAG

TAG

TAG

TAG

TAG

BRWN
BLE
BRWN
BLE
BRWN

BLE

TAG

BLE

BRWN

TAG

BRWN

TAG

BLE

BRWN
BLE
BRWN
BLE
BRWN
BLE
BRWN
BLE
BRWN
BLE

S1+

S0+

S1

S0

SEGMENT# 2

7+

3B

4B

SB
5+

S2+

S2

MODULE
DF51

JB
S3+

BT

S3
S4+

S5+

S4

S5

S1+

S0+

S1

S0

BT
SEGMENT# 3

7+

1B
2B

SB
S2+

5+

S2

4
JB

S3+
S3
S4+

S5+

S4

S5

S1+

S0+

S1

S0

MODULE
DF52

BT
SEGMENT# 4

7+

1
2
SB

S2+

5+

S2

4
JB

S3+
S3
S4+

S5+

S4

S5

BT

BT

NOTES
4

REV

DATE

DESCRIPTION
REVISIONS

FIG. 2.2k
Network drawing for intrinsically safe installation with multiple segments.

NETWORK DRAWING

DN CK EG AP AP
DWG #:

2.2 Intrinsic Safety Rules for Fieldbus Installations

BRWN

TAG

BLE

BLE

TAG

BRWN

SEGMENT# 1

165

2002 by Bla G. Liptk

166

Designing a Safe Plant

1 km for the FISCO model and even lower for the entity
concept.
13.8 9
-------------------------------------------------- = 1.1
3
12 10 8 2 22

2.2(3)

If the power supply output voltage is lower, or the device

power consumption is higher, the distance will be shorter.
Conversely, the opposite also applies. It is therefore critical
for both intrinsically safe and regular installations that the
device current consumption is as low as possible.
When dimensioning the number of devices per barrier
the worst-case device FDE current should be taken into
account. That is, leave a margin as wide as the device with
the highest FDE current so that this device can fail without
affecting others.
It is important that the barrier and field devices are all
FISCO certified. Non-FISCO barriers and devices cannot be
used in FISCO-style installations.
REPEATING BARRIERS
A fieldbus network can consist either of a single segment
or of several segments joined by repeaters to form a network.
Every network segment has a terminator in each end. For
non-intrinsically safe installations the network usually only
has a single segment, whereas for intrinsically safe installations several segments are used to form a network linking
the segments together using repeaters. It would be rather
uneconomical to connect only one barrier per host communication port because each safety barrier, in particular a
linear barrier, connects only a few devices. Some field
instruments have a current consumption so high that only
two can be connected to each linear barrier. It is possible
to run one safe area segment from the communication port
to several multidropped barriers provided that barriers
with built-in repeaters are used. Each repeating barrier has
a hazardous area segment, thus forming a larger network
with a full 16 devices per network (Figure 2.2j). If barriers with
built-in repeaters are used, external repeaters are eliminated.
A single network diagram replaces multiple-loop diagrams for installation documentation. A typical network
diagram for an intrinsically safe installation is shown in
Figure 2.2k.
There is a limit to the length of a network segment due
to the signal attenuation along the wires. A repeater refreshes
the timing of the signal received in one end and boosts the
level as the signal is regenerated in the other end using a
fieldbus controller chip. Thus, the repeater overcomes signal
attenuation by restoring the original symmetry and amplitude
of the signal. The repeater is bidirectional and typically galvanically isolated. Repeaters may thus also be used to connect
intrinsically safe segments together to form a larger network
with many devices.
Nonrepeating barriers have low impedance that loads the
network and also attenuates and distorts the communication

2002 by Bla G. Liptk

Host

Linking
Device
Safe Side
Segment

Barrier

Hazardous
Area
Segment

Repeater

Repeater

Repeater

Barrier

Barrier

Barrier

Hazardous
Area
Segment

Hazardous
Area
Segment

Hazardous
Area
Segment

FIG. 2.2l
Repeaters with separate barriers.

FIG. 2.2m
Fieldbus repeater. (Courtesy of Smar.)

signal as it passes through the barrier. Therefore, only one

such barrier per network is possible. However, by using
repeaters, the network can be divided into several segments,
each with one barrier (Figure 2.2l).
Every network segment must have a terminator in each end.
However, typically the repeater already has terminators built in
and all that need be done is to make sure that the terminators
are enabled or disabled as required (Figure 2.2m). Power must
also be supplied on separate terminals for the repeater.
It is helpful if the repeater is isolated and has a terminator
built in on both ports.
Every type of network uses a different kind of repeater.
Make sure to use a repeater designed with characteristics
according to IEC 61158-2 and not some other kind of bus.
Bibliography
Fieldbus Foundation, 31.25 kbit/s Intrinsically Safe Systems, Application
Guide AG-163, 1996.
Johannesmeyer, U., PTB report W-53e, Investigations into the Intrinsic
Safety of Field Bus Systems, Braunschweig: PTB, 1994.
PROFIBUS, Technical Guideline, PROFIBUS-PA User and Installation
Guideline, version 1.1, order No. 2.092, September 1996.