DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 1 of 11

TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER

SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

1.0 PURPOSE

This document is intended to provide the criteria to evaluate electrical apparatus,

or parts of such apparatus, that utilize active overvoltage or overcurrent
protection circuits that are intended to create intrinsically safe outputs.

2.0 SCOPE

These requirements apply to any circuit that uses some form of active voltage or
current limiting in whole or in part to provide an intrinsically safe output.

3.0 REFERENCES

3.1. 30 CFR Part 18 “Electric Motor-Driven Mine Equipment and Accessories”

3.2. 30 CFR Part 19 “Electric Cap Lamps”

3.3. 30 CFR Part 20 “Electric Mine Lamps Other Than Standard Cap Lamps”

3.4. 30 CFR Part 22 “Portable Methane Detectors”

3.5. 30 CFR Part 23 “Telephones and Signaling Devices”

3.6. 30 CFR Part 27 “Methane-Monitoring Systems”

3.7. ACRI2001 “Criteria for the Evaluation and Test of Intrinsically Safe
Apparatus and Associated Apparatus”

4.0 DEFINITIONS

Intrinsically Safe Active Voltage/Current Limited Circuit – A circuit that utilizes

non-passive components such as transistors or other solid state devices that
either shunt overvoltage or overcurrent conditions or limit the output of the
power source fast enough to prevent an ignition of a methane-air atmosphere.

5.0 CRITERIA

5.1. In addition to this criteria, the circuit must comply with all other applicable
parts of ACRI2001.

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01
 DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 2 of 11
TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER
SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

5.2. Documentation.

5.2.1. A detailed explanation on the operation of the circuit shall be supplied to

aid in the evaluation. This must include components comprising
overvoltage protection circuits, components comprising overcurrent
protection circuits, maximum trip settings of each
overcurrent/overvoltage circuit, the reset time between trips (note the
reset time may need to be reduced on the safety-factored circuit to aid in
testing as described below in section 5.7.1.1), and any other critical
features of the circuit such as circuitry that activates the protective circuits
based on the rate of change of the load current (di/dt).

Note: To aid in the spacing analysis of the circuitry, it is recommended

that all components of a particular circuit (e.g. overvoltage protection
circuit) are circled on the layout drawing and the minimum creepage and
clearance in these areas indicated. It is also recommended that either
Gerber files or transparencies of all layers of the circuit board are supplied
for verification of the creepage and clearance distances.

5.2.2. The final drawings must specify:

5.2.2.1. The maximum voltage and current settings for each active circuit
affecting intrinsic safety. This includes active limiting stages that
indirectly affect the output voltage and current, di/dt circuits, etc.

5.2.2.2. The maximum non-safety-factored output voltage and output current

for the power source with zero, one, and two faults applied. A circuit
using identical triplicate circuits would have the same voltage and
current for each quantity of faults.

5.2.2.3. Maximum acceptable directly connected load capacitance for zero, one,
and two fault conditions.

Note: This is not a requirement for application specific power sources.

Alternatively, the worst case capacitive circuit(s) comprised of internal
and/or external capacitance may be tested in combination with the
system.

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01
 DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 3 of 11
TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER
SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

5.2.2.4. Maximum source inductance appearing at the output terminals for zero,
one, and two fault conditions and the associated minimum resistance
for these conditions.

Note: This is not a requirement for application specific power sources.

Alternatively, the worst case inductive circuit(s) comprised of internal
and/or external series inductance will be determined during the system
evaluation.

5.3. Evaluation and Design Requirements.

5.3.1. All components of each protection circuit affecting intrinsic safety shall be
operated, in normal operation, at not more than 2/3 of their rated current,
voltage, or power, as appropriate (ref. ACRI2001 section 8.1.1). Special
attention must be applied to the evaluation of duplicative protection
circuits, since for most cases, it can be assumed that current, voltage, and
power are not shared among the duplicated circuits. Instead, due to
tolerances in the settings, only one of the duplicated circuits trips or
activates.

For example, three equivalent zener diodes or three identical active

voltage limiting circuits limit the output voltage of a power source. Each
zener diode or voltage limiting circuit shall comply with ACRI2001
section 8.1.1 since one will begin conducting or activating prior to the
other two.

5.3.2. A two fault analysis according to ACRI2001 shall be applied. Special

attention must be applied to the evaluation of duplicative protection
circuits, since for most cases, it can be assumed that current, voltage, and
power are not shared among the duplicated circuits. Instead, due to
tolerances in the settings, only one of the duplicated circuits trips or
activates. The ratings of components after the application of faults shall
be adequate to prevent subsequent faults.

For example, there are three active current limiting circuits that limit the
current to 2, 4, and 6 amperes to three equivalent zener diodes. In
accordance with ACRI2001 section 8.1.1, the zener diodes need to each be
rated 3A (2/3 rating at 2 amperes). However, to determine adequacy after
application of two faults (short circuit failure of the 2 and 4 ampere
current limiting circuits), each zener diode must be capable of

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01
 DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 4 of 11
TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER
SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

withstanding 6 amperes without failing in a manner that would affect

intrinsic safety.

5.3.3. When a single sense resistor is shared for multiple protection circuits, the
sense resistor must be connected to each protection circuit through
separate circuit board traces so that one common trace failure does not
disable all protection circuits. The resistor must also comply with
ACRI2001 as a protective current limiting resistor. Note: Infallible traces
are not an acceptable alternative according to ACRI2001.

Alternatively, the resistor does not need to be connected via separate

circuit board traces provided disconnection of the sense resistor maintains
an intrinsically safe output with up to two faults applied.

5.3.4. Circuits which are powered from an AC line and are not powered through
a protective transformer as defined in ACRI2001 must have input
protection that passes a two fault analysis per ACRI2001 for the AC line
voltage.

For example, if a power source is to be powered by 40 VDC which is

supplied by a 120 volt line powered, generic power supply that is not
documented, then the power source must withstand without damage that
would affect intrinsic safety, an input of 144VAC, or 1.2 times the nominal
line voltage for higher AC input voltages.

5.3.5. Since it is not feasible to conduct a spark ignition test at the instant an
overvoltage condition occurs, the overvoltage protection circuit shall be
accepted on the basis of its response time. The response time is
considered the time at which the maximum input fault voltage exceeds
the maximum trip voltage and returns to less than or equal to the
maximum trip voltage. For purposes of the test, the maximum input fault
voltage shall be simulated with a DC input voltage equal to the maximum
DC input voltage or maximum peak AC input voltage. A response time
of 100μS or less is acceptable without additional testing or justification
provided there is no damage that would affect intrinsic safety. Response
times in excess of 100μS shall be justified. The response time of the
overvoltage protection circuit of the non-safety factored version shall be
documented by means of an oscilloscope trace.

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01
 DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 5 of 11
TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER
SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

Factors to be considered in the justification of response times in excess of

100μS may include: probability of overvoltage and a short-circuit fault
condition occurring at the same time, level of the output voltage and
current during the overvoltage exposure time in excess of 100μS, whether
the overvoltage condition is a one time event (e.g. fuse blows) or could
occur multiple times, etc.

Note: The test shall be conducted by applying the worst case input
voltage and applying the two worst case faults according to ACRI2001.
Subsequent faults as a result of this test are not countable.

5.3.6. Where active circuit settings that affect intrinsic safety are adjustable, the
adjustable components must be inaccessible to the user and resistant to
vibration.

An example of an acceptable method is encapsulating potentiometers. An

example of an unacceptable method is the use of special fasteners on the
power supply enclosure.

5.3.7. The maximum source inductance appearing at the output terminals for
zero, one, and two fault conditions and the associated minimum
resistance for these conditions shall be verified. This data will be used in
the evaluation of the future connected inductive loads and either
compared with published spark ignition curves or tested to determine
acceptability.

5.4. Samples Required To Be Submitted.

5.4.1. One fully assembled version of the power source in marketable form for
testing and comparison to the drawings. If any of the circuitry is
encapsulated, then a second unencapsulated sample must also be
submitted for measurements and application of faults.

5.4.2. One fully assembled version of the safety-factored power source. If any of
the circuitry is encapsulated, then the submitted sample shall be
unencapsulated for measurements and application of faults. The
following requirements shall be included in the construction of the safety-
factored power source:

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01
 DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 6 of 11
TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER
SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

5.4.2.1. An electrical safety factor is required for all spark ignition tests of zero
and one faults. A safety factor obtained through the use of a more easily
ignitable gas is not acceptable. The safety-factored version of the power
source shall be adjusted to provide 1.5 times the output energy. This is
typically achieved by increasing the voltage/current by 1.225 times
each, with unaltered shut-down speed. Power sources employing
special features such as di/dt circuits shall also have these circuits safety
factored if necessary to achieve a 1.5 factor of safety on energy. Note:
The shut-down time may vary slightly due to the change in
voltage/current. If considered to be providing a less than desirable
safety factor, then the shut-down time will need to be decreased.

5.4.2.2. Care should be taken to construct the safety-factored power source as

close as practical to the marketable form version (e.g. equivalent
components such as transformers, voltage regulators, and transistors) if
possible, and in cases when this is not feasible, components shall be
chosen with similar characteristics or from the same family of
components.

5.4.2.3. The safety-factored power supply shall include either a description of

changes made to construct the safety-factored version, or a marked-up
bill of material and/or schematic to describe the changes.

Note: Reference note in section 5.7.1 regarding special test considerations.

5.5. Measurements. The following measurements shall be taken on both the

non-safety-factored and safety-factored versions of the power source. The
measurements shall be taken at 1.2 times the nominal voltage, unless
measurements at the nominal input voltage or less result in higher output
values.

5.5.1. Voltage and current measurements at critical stages of the circuit such as
output of the transformer, output of the rectifier, output of the rectifier
plus capacitance, output of the overvoltage protection, output of the
overcurrent protection, etc. Note: it may be necessary to open circuit
downstream circuitry to prevent any affect on the desired measurements.

5.5.2. Load lines (e.g. output voltage versus output current for varying resistive
loads including open circuit and short circuit) with all critical faults that
would affect the output characteristics. The purpose of these load lines is

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01
 DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 7 of 11
TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER
SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

to compare the safety-factored and non-safety-factored load lines for

similarity, and to document the characteristics of the non-safety factored
circuit for future testing/evaluation of connected devices. A minimum of
15 data points shall be obtained. Note: A voltage limiting circuit
consisting of a voltage regulator and two active voltage limiting circuits
will need to have a separate load line for multiple fault scenarios.

5.5.3. Oscilloscope traces of the output waveforms with all critical faults that
would affect the output characteristics. Additional oscilloscope traces
must be obtained to confirm special features of the power source such as a
di/dt circuit. The purpose of obtaining the oscilloscope traces is to
compare the safety-factored and non-safety-factored traces for similarity,
and to record the speed of the tested circuits for future reference.

5.6. Spark Ignition Testing General Requirements.

5.6.1. Testing should be conducted with only one of the identical duplicated
circuits to prove adequacy and reliability unless including multiple
circuits can be proven to be a more severe condition. Note: This may be a
more stringent test (e.g. two faults with a safety factor), but may be used if
it simplifies testing. Failure to pass this test does not imply the circuit is
unsafe. If a failure occurs, additional consideration to the worst case test
will need to be made.

5.6.2. Testing shall be conducted at 1.2 times the nominal input voltage (AC or
DC) unless testing at the nominal input voltage or less can be proven to be
a more severe condition.

5.7. Spark Ignition Tests.

5.7.1. The power source must be subjected to a minimum of 4,000 short circuit
make sparks, and 4,000 maximum current break sparks. Two
characteristics of active power sources may prevent a single continuous
spark ignition test of 1,000 revolutions to be the most severe test. If the
power source exhibits either of the following characteristics, then the
spark ignition testing of the power source output must include the
prescribed additional test(s). Note: Segmenting the test(s) is allowed (e.g.
four 1,000 cycle segments) provided a calibration is obtained before and
after each segment.

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01
 DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 8 of 11
TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER
SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

• If the active protected circuit shuts down on the first make short circuit
of the spark test apparatus, and does not reset quickly enough to the
maximum open circuit voltage between the break short circuit and the
next make short circuit of the apparatus, then the additional test
described by section 5.7.1.1 must be conducted.

• If the active protected circuit employs features such as di/dt circuits

that trip/activate on the make spark and result in a break spark of less
than the maximum output current, then the additional test described
by 5.7.1.2 must be conducted.

Note: It is the applicant’s responsibility to provide power source

samples for spark ignition testing to allow automated testing on the
spark test apparatus. Techniques used to manufacturer these samples
include: reset circuits, where none exist; modified reset circuits; or
outboard circuitry. Where this is not practical, the spark ignition
testing will be conducted by manually starting and stopping the spark
test apparatus. When these manual techniques are required, the fee
estimate should be increased to allow for the substantial increase in
test time.

5.7.1.1. The make-spark ignition test may either require stopping the electrodes
off of the disc to allow adequate time for the power source to reset or
reducing the quantity of electrodes to prevent stopping and starting of
the spark test apparatus. An oscilloscope trace shall be obtained and
included with the spark ignition test sheet to confirm adequate reset
time was allotted during the spark ignition test.

The time for a complete cycle of one electrode is approximately 750.0mS

(132.5mS X 4 plus 55mS X4). The spark test apparatus speed shall not be
reduced to allow for increased reset time.

Note: The standard disc with the two grooves must be utilized during
all spark ignition testing.

Below is a table listing the approximate reset times at 80RPM for the
quantity of electrodes installed, and the scope trace from which these
were calculated. The scope trace was obtained at 80RPM with four
electrodes installed using a non-typical disc without the two required
grooves.

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01
 DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 9 of 11
TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER
SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

Quantity of Electrodes Open circuit or reset time

4 55mS

2 242.5mS

1 617.5mS

Off time (electrode off disc)

Electrode Electrode Electrode Electrode Electrode

#1 #2 #3 #4 #1

On time (electrode on disc)

5.7.1.2. The break-spark ignition test may be conducted by either of the two
following methods:

5.7.1.2.1. By inserting a resistive load selected to draw an output current just

below the current trip point while maintaining continuous rotation of
the spark test apparatus, or

5.7.1.2.2. By stopping the electrode on the disc, reducing the variable resistive
load to obtain safety-factored current, and then starting the spark test
apparatus to initiate the break-spark.

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01
 DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 10 of 11
TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER
SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

5.7.2. Test(s) to determine the maximum acceptable capacitance across the

output for the worst case zero and one fault (safety-factored power
source), and two fault (non-safety-factored power source) conditions shall
be conducted. The test(s) is/are necessary to provide data for evaluating
applications utilizing capacitive loads since published spark ignition
curves only consider the energy stored in the capacitor and not the energy
from the power source. Note: Testing of an application specific power
source shall include worst case zero and one fault (safety-factored power
source), and two fault (non-safety factored power source) tests utilizing
the worst case capacitance values determined from the system evaluation.

5.7.3. If a power source includes features such as a di/dt circuit, then special
consideration has to be given to devising a spark ignition test that
simulates the worst case resistive loading condition for a make or break
spark. A detailed understanding of the operation of the circuit is required
to properly configure the spark test.

An example where another spark test may produce a more severe

condition than a direct short circuit is as follows: Assume the power
source has an ultimate trip value of 6A, and has a rate of change trip of
2A, a test in which the power source is loaded to 4A and then the load is
partially shorted to produce a 6A load may produce a more incendive
spark than a direct short (0 to 6A).

Alternatively, the di/dt circuit could be bypassed for testing. Failing the
spark ignition test with a triplicated di/dt circuit bypassed does not
necessarily constitute a failure.

5.7.4. Any additional tests deemed necessary.

5.7.5. Repeat the tests described by sections 5.7.1 through 5.7.4 using the non-
safety-factored power supply.

5.8. Conditions of Use. The approval letter shall include the following
conditions of use for active circuits that are not application specific:

5.8.1. Nominal input voltage.

5.8.2. If the power source has multiple output voltage and/or current settings,
then all MSHA approved power sources must be marked so the user can

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01
 DOCUMENT NO: ACRI 2011 VERSION: 2008-03-20 Page 11 of 11
TITLE: INTRINSICALLY SAFE ACTIVE VOLTAGE/CURRENT POWER
SOURCE CRITERIA
MSHA Mine Safety and Health Administration, Approval & Certification Center

determine the voltage/current version. This may be accomplished by

marking each power source with the voltage and current setting, by
model number, by MSHA approval number, or any similar method.

5.8.3. Any other conditions of use deemed necessary.

5.9. Final Report Documentation. In addition to documenting how the power

source complies with this criteria and ACRI2001, the final report is also
required to include the following:

5.9.1. The maximum voltage and current settings for each active circuit affecting
intrinsic safety. This includes active limiting stages that indirectly affect
the output voltage and current, di/dt circuits, etc.

5.9.2. The maximum non-safety-factored output voltage and output current for
the power source with zero, one, and two faults applied. A circuit using
identical triplicate circuits could have the same voltage and current for
each quantity of faults.

5.9.3. Maximum acceptable directly connected load capacitance for zero, one,
and two fault conditions. As an alternative for application specific power
sources, the worst case situation(s) may be tested.

5.9.4. Maximum source inductance appearing at the output terminals for zero,
one, and two fault conditions and the associated minimum resistance for
these conditions. As an alternative for application specific power sources,
the worst case situation(s) may be tested.

ACRI2011 2008-03-20.doc Print Date: 3/20/2008

PRINTED AND ELECTRONIC COPIES OF THIS DOCUMENT ARE
UNCONTROLLED. VERIFY CORRECT VERSION PRIOR TO USE. TCRI0001, Rev 01