Customer Application

Intrinsically Safe in the Ex Area

With its 750 XTR Series of products, WAGO has offered a solution since 2014 that broadens the range of use for machines and systems with regard to environmental conditions and external interference factors, while providing the highest degree of flexibility. Temperatures ranging from a frigid −40°C to a hot 70°C, vibrations up to 5g or elevations up to 5,000 m above sea level: The WAGO-I/O-SYSTEM 750 XTR can be used everywhere. It also has increased immunity to impulse voltages and interference in accordance with EN 60870-2-1.

From the start, WAGO has continuously developed and optimized the 750 XTR Series for customers around the world. WAGO has defined a new dimension of use with the latest development for the 750 XTR Series. One thing is certain: The new intrinsically safe I/O modules not only like it both hot and cold, they are also available for hazardous areas.

Additions to Flexibility: 750 XTR

eXTReme temperature range: −40°C … +70°C
eXTReme immunity to impulse voltages and interference (EN 60870-2-1)
eXTReme vibration resistance: 5g (EN 60068-2-6)
eXTReme continuous shock resistance: up to 25g (IEC 60068-2-27)
eXTReme intrinsic safety (signal acquisition from Zones 0 and 1)
Short-term condensation per Class 3K7 (EN 60721-3-3)
Operating altitude: up to 5,000 m above sea level
Approvals: UL, ANSI/ISA, ATEX/IECEx, marine systems (e.g., DNV GL, ABS)
Installation location: Zone 2/22

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The Story

Strict Requirements on Engineers and Machines

Engineers are constantly faced with the challenge of designing machines and systems as economically and effectively as possible while still providing a finished product for the world market. The jungle of import regulations, local standards and guidelines is a complex determining factor. Much more obvious, and at least as demanding, are the different and sometimes extreme environmental conditions in which the equipment is used. Conditions range from moderate temperatures in Central Europe to strong temperature fluctuations between day and night in Central Asia, to high humidity in Indonesia, to extreme aridity in the Andes, to ice-cold Siberian winters. Mobile systems must also cover as broad a range of applications as possible. A drilling rig may be deployed just off the coast of Brazil, in the high altitude deposits in northern Norway and Canada or in the middle of the Arabian desert. The same applies to the deck superstructures of tankers or cargo liners that maneuver on our world’s oceans.

Maximum Flexibility beyond Zone Boundaries

With its latest innovation of the XTR Series, WAGO provides a system that can be used for signals both from non-hazardous areas and from areas that are intrinsically safe. The WAGO-I/O-SYSTEM 750 XTR can be used both outside of hazardous areas and within Zone 2/22 inside an approved enclosure. All modules have ATEX/IECEx approval for use in Zone 2/22. In addition to standard signals from sensors and actuators in Zone 2/22, intrinsically safe sensors and actuators in Zones 0/20 and 1/21 can also be integrated via the I/O modules in the blue housing. The intrinsically safe part of the control system must be started with the Ex-i bus supply module; this regulates the input voltage of 24 V (−25% to +30%) to 24 V +/- 0.3 V, limiting it to max. 26.8 V in case of failure. The module thus prevents ignitable sparks from occurring in case of failure.

The Right I/O Module for Every Field Device

To protect against possible interference from the non-intrinsically safe area of the control system, the Ex i power supply is installed in a wider housing that ensures the required safety distance of 50 mm. The narrow 12 mm or 24 mm modules for digital and analog input and output signals, temperature measurements via resistance sensors and potentiometers or counter signals are connected to the right of the Ex i power supply. Up to eight channels are available, depending on the module. Up to three secondary variables can be read via the HART protocol, in addition to the main variables, via one of the 2-channel analog input modules (750-484/040-000). This can help to omit additional measuring points in corresponding layouts. Whether shut-off valve limit switches, slider magnetic valves or regulator valve control and position feedback, the 750 XTR Series provides the right intrinsically safe I/O module for every field device.

The 750 XTR Controller

Extremely temperature-resistant, immune to interference, as well as unfazed by vibrations and impulse voltages: WAGO's 750 XTR Controller is the robust solution for small control tasks.

eXTReme Properties for Extreme Requirements

The XTR in the module designation stands for “eXTReme” environments. The permissible ambient temperature range of −40°C to +70°C enables the modules to be used an any climatic zone without having to provide additional protection with air conditioning or heating systems. The module's immunity to impulse voltages and interference even permit it to be used in medium-voltage systems. Furthermore, due to their extreme vibration and shock resistance, the XTR modules for the intrinsically safe area even meet the requirements for rail vehicles and are suitable for installation on marine diesel engines. All of the circuit boards are coated with protective varnish, to safeguard the power electronics and conducting tracks against short-term condensation.

750 XTR: Versatile, Future-Ready and Reliable

This combination of intrinsic safety requirements with resistance to environmental extremes makes the WAGO-I/O-SYSTEM 750 XTR invaluable for oil and gas industry systems in the upstream sector (extraction, processing) and downstream sector (transport, refining), or outdoor systems exposed to extreme temperature cycling. The WAGO-I/O-SYSTEM 750 XTR functions not only as a purely remote I/O system, but also offers a versatile, future-oriented and reliable control system with the high-performance PFC controllers.

Increased Efficiency and Cost Minimization

The WAGO-I/O-SYSTEM 750 XTR facilitates the development of optimized and globally applicable automation concepts for systems and machines. This makes it possible to reduce the dimensions for air-conditioning and ventilation systems, or omit them, and to lower the cost of overvoltage protection. Manufacturer expenses related to product support and maintenance and storage costs at the end customer are also minimized. Manufacturers and operators thus benefit from numerous advantages.

Authors: Benjamin Böhm, Manfred Kühme | WAGO

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Bridge approval based on IEC EN 60945
Classified for extreme environments (approved for use in the engine room)
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Customer Application Intrinsically Safe in the Ex Area