Shunt-Diode Safety Barriers and Galvanic Isolators a Critical Comparison

By L C Towle BSc CEng MIMechE MIEE MInstMC Technology Director The MTL Instruments Group plc

TP1113-2 June 1996

Introduction
The discussion on the relative merits of galvanic isolators and shunt diode safety barriers has been carried on for many years. The majority of other articles on this subject have aimed to prove the superiority of one technique over the other. This paper brings together the illustrations which have accumulated over a considerable time in response to various questions raised at presentations. It attempts to make balanced arguments so that the reader can decide the most suitable technique for a particular application. It ends with a score sheet which might be found useful if a decision is not completely self revealing. The paper has evolved over a considerable time, however it is unlikely that it covers all aspects and will inevitably need to be revised as techniques develop. If you have any comments on the contents or omissions within this document the author would like to receive them. In this way the document will become more comprehensive and more valuable.

Figs 1 and 2
The basic function of an intrinsicallysafe interface is to remove the necessity for certifying the safe-area equipment. The equipment in the safe area is usually complex, needs to be flexible and contains considerable power. Therefore it can inject significant levels of energy into the hazardous area, particularly under fault conditions. An ideal interface allows the normal low energy signal to pass with as small a voltage drop as possible and with very little attenuation. If however a fault develops in the safe-area equipment then the interface changes its transfer characteristic and restricts the energy transferred to the hazardous area to a safe level. Shunt-diode safety barriers were developed in the late 1950s as process control computers were more widely applied to the chemical industry and are generally regarded as being the older technique. However, intrinsically-safe relay isolators for switch inputs have been available for many years (quite how many I have not been able to establish) and analogue isolators were available in 1953. The recent growth in the use of both types of isolators has resulted from improved performance and lower cost, not to any change in fundamental principles.
Separately or together
HAZARDOUS AREA SAFE AREA

Certified hazardous area apparatus

Certified interface

Uncertified safe area apparatus eg: Computer

Um: 250v

Uncertified simple apparatus

Intrinsically safe interface

Barriers
Concept 1958 Redding Approved 1961 Gresham Kent

Isolators
Switch Analogue Telemechanique 1950's Pepperl & Fuchs Evershed & Vignoles 1953 MTL 1974

History

Fig 3 and 4
Fig 3 illustrates how a shunt diode safety barrier is constructed so as to limit the current and voltage available from the hazardous-area terminals. The fuse restricts the fault power, the zeners restrict the voltage and the current limiting resistor [CLR] restricts the current.
HAZARDOUS AREA SAFE AREA

Intrinsic Safety earth

CLR RO IO VO

Barriers are usually described in terms of their safety parameters: 28V 93mA 300R is a common barrier safety description where VO = 28 volts Current Limiting Resistor (RO) = 300R

Shunt diode safety barrier

2

The galvanic isolator illustrated in Fig 4 breaks any direct connection between safe- and hazardous-area circuits by interposing a layer of insulation between the two. The power transfer is usually via some form of transformer and the return signal via an optocoupler, transformer, or relay. The final power limitation is achieved by using a diode resistor network very similar to that of a shunt-diode barrier.
Hazardous area connection
HAZARDOUS AREA SAFE AREA

Energy-limiting

Hazardous area circuit

S A F E T Y S E G R E G A T I O N

Certified component

Safe area circuit

Safe area connection

Certified transformer

Power
4

Galvanic isolation

Figs 5 and 6
Since the hazardous-area circuit from an isolator is not directly connected to the safe area circuit, it is usual to regard the fundamental action as effectively blocking the excessive energy at the layer of insulation. In practice the 0V of the instrument system is normally returned to the neutral star point for interference avoidance and safety reasons. The resultant fault current is thus returned to the neutral star point in the usual way, rupturing the protective fuse and removing the fault, in a relatively short time. The conventional fault consideration of the shunt-diode barrier is illustrated in Fig 6 where the fault current is returned to the neutral star point within the safe area in much the same way. The important difference is that the transient voltage difference between the barrier busbar and the neutral star point [X1 X] is now transferred to the hazardous area and hence must be restrained to a low level [less than 10V]. In consequence the busbar to neutral star point bond on the shunt diode safety barrier must be of low resistance and be secure, since it is critical to safety.
Isolated internal components Plant bond Barrier Busbar X1 L N E X Field mounted instrument Instrument system Isolated internal components Plant bond 0V Field mounted instrument Instrument system

Galvanic Isolator under fault condition

Barrier under fault condition

Fig 7
Fig 7 lists the relative merits of isolators and barriers and the significance of these factors varies with the particular installation. The remainder of the document expands these points of comparison so that they can each be evaluated.

Barriers
Simple
Versatile

Isolators
Complex low MTBF Application specific High dissipation (2VA) Separate power supply Wider range power supply

Low dissipation
Loop powered Tightly controlled supply Restricted voltage available in hazardous area

Higher voltage (power) available in both hazardous area and safe area
Lower packing density

Higher packing density

Safety earth fundamental Imposes a reference 0 volt on system Circuit must be isolated from earth in hazardous area

Safety earth reduced significance Isolation between signals

Circuit may be earthed at one point in hazardous area Lower accuracy and linearity (0.25%)

Accuracy and linearity higher (0.1%) Lower cost Good frequency response [100KHz]
Encapsulated , irrepairable

Increased cost Limited frequency response Can be repaired

Vulnerable to lightning and other surges. Acceptable solution in most parts of the world

Less vulnerable to lightning and other surges. Preferred solution in marine installations and Germanic zones of influence
7

Comparisons

Figs 8, 9 and 10
In general the lower number of components and basic simplicity of the shunt-diode safety barrier means they are considered to be more reliable. A more accurate comparison has to compare the reliability of an isolator with the barrier plus additional components required to accomplish the same function. For example Figs 9 and 10 show the usual switch contact transfer using a barrier relay combination which should be compared with the more complete functions of the isolator. This reduces the apparent superiority of the barrier.

Barriers
Simple

Isolators
Complex (low MTBF)

Isolator has more components, comparison should consider total functional components. Isolator less vulnerable to supply variations

(70yrs)
(35 yrs with relay)

(18yrs)
Comparisons
8

HAZARDOUS AREA

SAFE AREA

MTL 787S Diode Return Barrier

24V+

Field switch is normally closed, open on alarm

Relay coil

IS Bond

Switch with Zener Barrier: preferred solution

4

HAZARDOUS AREA

SAFE AREA

Line fault detect resistors

Load, alarm or shutdown circuits

Field switch is normally closed, open on alarm

Supply

Plant reference potential

Digital Input

Switch with Galvanic Isolator

10

Figs 11 and 12 and 16

In general barriers are more versatile than isolators. For example the MTL787S barrier of Fig 16 is identical with that used in the switch application of Fig 9. If the flexibility of barriers is exploited to solve a new application then an analysis taking into account possible resistive drops and leakage currents is desirable, as indicated in Fig 16. Whenever a different untried combination of an intrinsically safe interface and field mounted equipment is proposed, it is advisable to try an experimental interconnection under laboratory conditions. A satisfactory trial increases the probability of the final installation working. Fig 12 shows an isolator for use with a conventional 4 to 20mA transmitter. The isolator is designed for use with this type of transmitter and is not useful for any other function.
Power supply 4-20mA 17.5V 300R 28V Typically up to 800R
HAZARDOUS AREA SAFE AREA

Barriers
Versatile

Isolators
Application specific

Isolators usually designed to solve a particular problem with limited flexibility Barriers: more than one application, but require applicational analysis. Compatability trials desirable in both circumstances

Comparisons

11

Isolation

Load

Power supply 20-35Vdc

Isolator for 2-wire transmitters

12

Fig 13
Isolators require additional power which utilises space, dissipates more heat and increases cost. The use of a well ventilated (possibly force ventilated) cabinet becomes a necessity if isolators are closely packed. It must be remembered that for both barriers and isolators the maximum permitted ambient temperature is the air temperature immediately adjacent to the apparatus i.e. the temperature inside the enclosure. This temperature may be raised by other adjacent electrical equipment.

Barriers
Low dissipation

Isolators
High dissipation

Isolators require 1-2VA for added signal power Temperature rise in large cabinets can be a problem Barriers dissipate very little 500mW 500 isolators yield 1Kw 30C rise in 2 meter high unventilated rack

Comparisons

13

Figs 14, 15, 16, 17, and 18

Barriers may have over-voltage protection to counteract large supply variations but the protection absorbs line volts. Conventional barriers restrict the available hazardous-area line volts. For example, the conventional diode return barrier transmitter combination of Fig 16 has a maximum line voltage drop of 0.9V. By comparison the MTL3041 circuit of Fig 17 has 5.5V available for line voltage which readily permits the use of loop powered local indicators as shown in the diagram.

Barriers
Loop powered Tightlycontrolled supply

Isolators
Separate power required Wide range power supply

Isolator - higher power available for both hazardous and safe area. Variable supply Barrier - dissipates some power but can be used in existing circuits

Comparisons

14

Barriers
Restricted voltage in hazardous area

Isolators
Higher voltage (power) available in hazardous area

Isolators inject voltage to replace losses Barriers absorb available voltage

Comparisons
6

15

Active barriers such as the MTL706 shown in Fig 18 permit more line voltage and are tolerant of supply voltage variation. They consume additional power, but offer an alternative to isolators if there is a strong preference for a barrier solution.
12V 4-20mA
HAZARDOUS AREA SAFE AREA

6.8V 340R max MTL 787S+

V+25.1V 26.0V

Instrument
1-5V 250R

20R + 0.9V 1.3V

0V

IS Bond

Transmitter with diode return barrier (MTL 787S) 16

HAZARDOUS AREA

SAFE AREA

12.73 C
Isolation 1V 12V 4-20mA 17.5V 300R 28V 16V 4-20mA Power supply + 20-35V dc.

MTL 3041

Loop-powered 4-20mA Indicator

17

HAZARDOUS AREA

SAFE AREA

22V-35V
40mA max
Protect Regulate

50mA

TX
15V

300R 28V
Floating supply 4-20mA

250R load

IS Bond 0V

MTL 706 schematic

18

Figs 19 and 20
The number of interfaces which can be mounted in a cabinet is largely determined by the size of cabling to be accommodated and the degree of accessibility to be achieved. Facilities for cross wiring also use considerable amounts of space. The numbers quoted are those for generously designed racks and higher density can be achieved at the expense of accessibility and temperature rise. The figures available do however demonstrate the higher packing density which can be achieved with barriers. The number of mechanical variations available in both barriers and isolators is increasing and each has its particular merits.

Barriers
High packing density

Isolators
Low packing density

Isolators physically larger than barriers For some functions barriers require additional equipment In practice rack size is affected by cable trunking, termination of screens and armour Traditionally U.K. barriers were busbar mounted DIN rail mounting for both barriers and isolators now commonplace Backplane mounting, with plug in facilities available for both interfaces Multichannel interfaces save space, but sacrifice individual loop integrity

Comparisons

19

Cabinet
The discrete use of multichannel units can also effectively increase the number of channels per cabinet. However single loop integrity is sacrificed and some thought as to whether this is significant or not is essential.

600 x 600 x 2100mm without crosswiring

MTL 700 400 units MTL 7000 650 units MTL 3000 192 units allows for Power Supply MTL 4000 256 units

Interface Numbers in Cabinet

20

Figs 21, 22, 23, 24 and 25

There is normally much emphasis on the necessity for correct bonding of the shunt-diode safety barriers 0 volt busbar. However the development of the required bonding system from Fig 22 showing the requirements for structure, computer 0V and screen to the slightly modified system of Fig 23 illustrates that there is no difficult requirement. To avoid significant differences within the hazardous area the bond should have a low resistance [0.1] and be of high integrity. The
8

Barriers
Safety earth fundamental

Isolators
Safety earth has reduced significance

Isolators - require consideration of bonding of screens or bond for interference avoidance Barriers - return path for fault current essential

Comparisons

21

possibility of installing a second lead (as indicated by the broken line) for monitoring purposes should be considered. However the presence and integrity of the bond is essential in all types of installation. The isolator bonding system illustrated in Fig 24 is identical with that of the non-hazardous system, but the 0V bond has some safety implications. The overall earthing system illustrated in Fig 25 emphasises that the instrument system bonding is only a part of the total system. The requirements are only marginally affected by whether barriers or isolators are used.
0V 24V Computer

Standard bonding practice

22

Computer 24V

0V

HAZARDOUS AREA

SAFE AREA

Shunt diode safety barrier bonding system 23

HAZARDOUS AREA SAFE AREA

Galvanic Isolator 24V

0V

Galvanic isolator bonding system

24

Plant
Interface cabinet

Control room
System cabinets

Sub station transformer

Screen Luminaire Armour

Barrier 0V

Computer 0V

Motor

Electrical distribution busbar

0V Clean busbar

0V Power busbar

Plant bond (structure + conductors + soil) Lightning earth Power system earth

Plant bonding

25

Figs 26, 27 and 28

Where signals have to be transferred across a hazardous area using intrinsically-safe cabling, the preferred technique is to use galvanic isolation at both ends. Fig 27 illustrates a system frequently used between analyser houses and control room. If a signal has to be transferred to a remote location in the safe area, Fig 28, the use of an isolator at the interface removes concern over possible potential differences between earth mats. The extra voltage needed to drive the interconnecting cables is also useful. For these reasons isolators are the preferred solution, in these particular circumstances.
SAFE AREA HAZARDOUS AREA SAFE AREA

Barriers
Imposes a reference 0 volt on system

Isolators
Isolation between signal and power supply

Isolators usually have 3 port isolation. Interaction between circuits reduced. Fault mechanisms easier to define Barrier 0 volt and computer 0 volt usually interconnected. Two channel barriers create pseudo 'earth free' circuits Barrier circuits bonded at barrier '0' volt, hence must be isolated elsewhere. Isolation necessary for transfer across a hazardous area or to remote situation

Comparisons

26

MTL 3058 (RS232C) or MTL 3059 (RS422A)

RS232orRS422 linkto processcontroller

MTL 3058 (RS232C) or MTL 3059 (RS422A)

RS232orRS422 linkto processcontroller

Tx Rx

Tx Rx

20-35V dc

Common

20-35V dc

Serial data transfer across a hazardous area 27

10

HAZARDOUS AREA

SAFE AREA

Plant Data Collection Centre

Remote Computer Centre Distance > 200m

0V Plant Supply Plant Mains Supply Plant Bond

Signal transfer to remote computer

28

Fig 29
There is a general requirement that intrinsically-safe circuits should be earthed at one point only and elsewhere isolated to withstand a 500V insulation test. It follows that where a sensor or some other field apparatus cannot be insulated (eg. a pH sensor) then the preferred solution is to use an isolator. In some countries the code of practice permits the using of equipotential bonding conductors but this is not a universally accepted practice and should be avoided if at all possible.

Barriers
Circuit must be isolated from earth in the hazardous area

Isolators
Circuit may be earthed at one point in hazardous area

Requirement of intrinsically safe circuits Earthed at one point only Elsewhere insulated to 500V If sensor already earthed eg. bonded thermocouple, best to use an isolator Universally accepted Barriers can be used with potential equalising conductor in some countries (eg UK), but messy

Hazardous area isolation

29

Barriers
Accuracy (0.1%) and linearity higher

Isolators
Accuracy and linearity lower (0.25%)

Isolator process for analogue signals has several conversions. hence lower accuracy Barrier does not distort current signals. Leakage currents very small Digital signals do not lose accuracy

Comparisons

30

11

Figs 30, 31, 32 and 33

Although the changing technology of isolators has increased their accuracy, they are in general less accurate than barrier systems. Usually transfer accuracy is adequate but the temperature coefficient remains significant. Figs 31 and 32 show comparable load cell systems where every effort is made to achieve maximum accuracy. The barrier load cell system can achieve 0.05% without difficulty, and the isolator system would achieve 0.25% if the ambient temperature varied by 25C. Fig 33 shows a Smart transmitter which when used with a 4 to 20mA analogue signal would expect to generate a 0.2% error at the interface. If, however, the digital representation of the measurement was used then the isolator would not introduce any error. It follows therefore that where isolators are the preferred solution for use with Smart transmitters and the highest accuracy is required then the digital signal should be used.
Multiple compensated load cells Certified Interface
+20 to 35V 0V

HAZARDOUS AREA

SAFE AREA

End-to-end resistance variation Line loss variation Supply Constant excitation voltage No voltage drop due to high impedance circuits Sense

Signal 0V

6-wire connection minimised error

31

HAZARDOUS AREA

SAFE AREA

Intrinsically safe power supply

MTL3992

Intrinsically safe load cell power supply

32

HAZARDOUS AREA

SAFE AREA

HHC*

MTL4041

20-35V dc +
4/20mA

I I

Load

HHC* Smart transmitter *Hand-held communicator

Plug-in isolator with transmitter

12

33

Figs 34, 35 and 36

Cost comparisons are always difficult because there is very rarely a precise coincidence of function. There is however a general perception that shunt diode safety barriers are less expensive than isolators. In practice for switch transfer purposes there is little difference in cost per channel between the two techniques. If individual loop integrity and minimum facilities are acceptable the multichannel switch isolators are lower in cost than corresponding barrier solutions as illustrated in Fig 35. Analogue isolators are more complex than the corresponding barriers and the cost difference becomes significant as shown in Fig 36. However, except for very large installations the cost difference is rarely the deciding factor.

Barriers
Lower cost

Isolators
Increased cost

Isolators for analogue signals more expensive than barriers Switch inputs cost difference small. Possibly lower cost per channel with isolators

Comparisons

34

50
Cost per channel MTL 787S Shunt diode barrier

Single channel Isolator

Two channel Isolator

Cost of switch interfaces

Three channel Isolator

35

100
MTL 3046B Smart isolator

50
MTL 787S Shunt diode barrier

Cost of analogue transmitter interfaces

MTL 706 Actice shunt diode barrier

MTL 3041 Isolator

36

13

Fig 37 and 38
In general the frequency response of a barrier is determined by the value of the current limiting resistor and the diode capacitance. The diode capacitance is non-linear with voltage and hence some distortion of any high frequency signals inevitably takes place and a discussion on frequency response can be misleading. If a system frequency is higher than 50kHz the only solution is to try the system experimentally, attempting if possible to allow for the effects of interconnecting cables. Isolators in general have to be designed to operate at the specific frequency transmitted. For example, with Smart transmitters the interface MTL3046B illustrated in Fig 38 works with the majority of transmitters, but not all. It is therefore essential to check compatibility between the particular apparatus and the isolator to be used.
4/20mA
15V 300R 28V

Barriers
Good frequency response

Isolators
Limited frequency

Isolators - limited frequency spectrum Designed for specific frequency band Barriers - 3dB at 100khz Note: Diode capacitance is non linear with voltage

Comparisons

37

HAZARDOUS AREA

SAFE AREA

HHC*

MTL3046B
Isolation

HHC*

Load

Power supply 20-35V dc

*Hand-held communicator

Isolating interfaces for smart transmitters

38

Fig 39
In general repair is not a practical proposition. Some thought on the acceptability of barriers with interchangeable fuses needs to be given if frequent damage is anticipated and cannot be avoided.

Barriers
Encapsulated

Isolators
Can be repaired

Isolators usually have fused primary and can theoretically be repaired Usually not economic Barriers encapsulated, hence throw away item

Comparisons
14

39

Figs 40, 41 and 42

Where there is a significant probability of potential differences across a plant due to severe electrical faults or lightning then isolators have greater immunity to damage. Fig 41 illustrates a possible problem with barriers. A fault current from the electric motor returns via the plant bond generating a voltage between points X and Y. If this is the case, break down occurs between the thermocouple and tank creating a potential hazard. The shunt diode barrier will sacrificially protect the instrumentation. Intrinsically-safe isolators are routinely tested to withstand 2.5kV rms and hence offer some degree of protection to the instrumentation system. Figs 42 shows how the use of an isolator together with a suitable surge suppression network can prevent an unacceptable voltage difference occurring within the Zone 0.
Zone O THC X Vxy Shunt Diode Barrier Instrumentation Fault current Protective conductor and structural bond
HAZARDOUS AREA SAFE AREA

Barriers
Vulnerable to lightning and other surges

Isolators
Less vulnerable to lightning and other surges

Transient surges caused by lightning and faults in electrical apparatus cause potential differences across plant Equipment in Zone O principal cause for concern Barriers used with surge suppression units cause multiple earth problems

Comparisons

40

Protection Network

Shunt diode safety barrier fault current

41

HAZARDOUS AREA

SAFE AREA

100,000A Surge Suppression Network

Protective Network 1000V

Instrumentation

Zone O PE 10,000A

90,000A

Preferred isolator - surge protection solution 42

15

Fig 43
The need to minimise the number of techniques used within an installation is obvious. Usually therefore, if a plant already uses shunt-diode barriers or isolators in most circumstances it is better to maintain a consistent practice.

If installation already exists and is predominantly a shunt diode safety barrier or an isolator installation then continue the same practice

1) Training of technicians 2) Spares 3) Mounting probably cheaper and more convenient

Overiding considerations

43

Fig 44
Historically, the need to avoid circulating current in ships hulls has led to the preferred practice of using isolated circuits. In general using shuntdiode safety barriers does not lead to any problems but the arguments are long and expensive. Similarly, German engineers are trained to use and prefer galvanic isolated circuits.

Barriers
Acceptable in most areas of the world

Isolators
Preferred solution in marine installations and German zones of influence

Marine regulations propose isolated circuits to avoid currents in hull Easier to use isolators than argue about 2 channel barriers German attitude German engineers prefer galvanic isolation particularly in Zone 0 Easier to to agree than convert

Particular situations

44

Figs 45 and 46
The score sheets principal function is to make sure you consider each of the contributing factors. If you have a preferred technique then pursue that line, since either solution will probably be satisfactory.

Allocate marks out of 10 if the requirement is important. eg. 8-2 Allocate marks out of 6 if the requirement is significant. eg. 2-4 Allocate no marks if the requirement has no significance. eg. 0-0 If total show a significant preference then follow the choice If the argument is balanced then follow your personal preference Whatever you do, use MTL equipment

Score sheet
16

45

Barriers
Prefer Barriers Existing system predominately barriers Simple Versatile Low dissipation Loop powered Tightly controlled supply Restricted voltage available in hazardous area Higher packing density Safety earth fundamental Imposes a reference 0 volt on system Circuit must be isolated from earth in hazardous area Accuracy and linearity higher (0.1%) Lower cost Good frequency response [100KHz] Encapsulated , irrepairable
Vunerable to lightning and other surges. Acceptable solution in most parts of the world Total

Rating

Isolators
Prefer Isolators Existing system predominately isolator Complex low MTBF Application specific High dissipation (2VA) Separate power supply Wider range power supply Higher voltage (power) available in both hazardous area and safe area Lower packing density Safety earth reduced significance Isolation between signals Circuit may be earthed at one point in hazardous area Lower accuracy and linearity (0.25%) Increased cost Limited frequency response Can be repaired

Rating

Less vulnerable to lightning and other surges. Preferred solution in marine installations and Germanic zones of influence Total

Score sheet

46

17