Why Intrinsic Safety Matters
When working in hazardous environments such as oil & gas drilling, chemical plants, and mining operations, safety is paramount. These industries frequently handle hazardous gases, vapors, or combustible dusts, where even a small spark could lead to catastrophic consequences.
For engineers tasked with tank level monitoring, process control, and automation. Intrinsically Safe Ultrasonic Sensors are a proven choice. Their non-contact measurement capabilities make them ideal for monitoring liquids and solids without risk of contamination or wear. But when these sensors are deployed in Zone 0, 1, 2, 20, 21, or 22 for ATEX/IECEx, and Class I, II, or III for UL/cUL environments, they must be paired with equipment that ensures electrical energy levels remain safely below ignition thresholds. That’s where intrinsic safety barriers come in.
The Role of Intrinsic Safety Barriers
A safety barrier is a protective device that limits the energy, voltage and current that enters a hazardous location. By incorporating Zener diodes, resistors, and fuses, the barrier ensures that any fault condition will not produce enough energy to ignite an explosive atmosphere.
This makes barriers an essential part of meeting ATEX, IECEx, and UL/cUL approval requirements. Without them, Intrinsically Safe Ultrasonic Sensors cannot be used in hazardous locations/explosive atmospheres, regardless of their own approvals.
For engineers, the barrier is not just an accessory, it’s the enabling link that allows Intrinsically Safe Ultrasonic Sensors to perform their job reliably in hazardous conditions.
Challenges in Hazardous Tank Level Monitoring
Consider a chemical processing plant storing volatile solvents, or a mining operation with dusty silos. Operators need real-time, continuous level measurement to prevent overfilling, and process interruptions.
Installing a standard sensor in these environments introduces risks:
- Electrical faults in wiring could spark.
- Excess energy from the control system could exceed safe limits.
- Without proper safeguards, even approved sensors cannot legally be operated.
By combining an intrinsically safe ultrasonic sensor with a properly approved safety barrier, engineers can achieve compliance and ensure uninterrupted monitoring.
ZSB-409A: Migatron’s 3-channel Zener Safety Barrier
The Migatron ZSB-409A is a purpose-built solution for engineers who need simplicity. It is a 3-channel positive polarity Zener diode safety barrier designed for use in Intrinsic Safety applications.
Key features include:
- Compatibility: Works seamlessly with Migatron’s RPS-409A-IS2, and RPS-409A-IS3 ultrasonic sensors.
- Three channels: One 24 VDC channel and two 10 VDC channels, combining multiple connections into a single compact device.
- DIN rail mounting: Fast, secure installation in control cabinets.
- Built-in grounding wire: Provides a safe discharge path for energy diversion.
- Safety Approvals: Approved for Class I, II, and III hazardous locations, with ATEX, IECEx, and UL/cUL
- Durability: Operates reliably across a wide ambient temperature range of –40°C to +60°C
By integrating these functions, the ZSB-409A reduces wiring complexity and ensures compliance while saving valuable control panel space.
Application Example: Hazardous Tank Level Monitoring
In an oil & gas refinery, a tank filled with volatile liquids needs constant monitoring to avoid overfill incidents. An RPS-409A-IS2 ultrasonic sensor provides the measurement, while the ZSB-409A barrier ensures that no unsafe electrical energy enters the hazardous area.
Similarly, in a chemical processing facility, where dust and vapors create a dangerous atmosphere, engineers can rely on the barrier + IS sensor combination to maintain compliance and keep operations running without risk of ignition.
In both cases, the ZSB-409A acts as the essential safeguard that makes intrinsically safe sensing possible.
Advantages of Using ZSB-409A with Migatron IS Sensors
When paired with Migatron’s IS sensor family, the ZSB-409A delivers:
- Turnkey compatibility: engineered specifically for RPS-409A IS sensor product line, reducing integration problems.
- Simplified wiring: three channels in one compact module.
- Compliance assurance: certified for use in hazardous environments worldwide.
- Reliability: rugged polyamide housing with humidity tolerance up to 95% non-condensing.
This combination provides engineers with confidence that their tank level monitoring systems meet safety standards without compromising performance.
Conclusion
In hazardous environments, safety and reliability cannot be optional. Ultrasonic sensors provide accurate, non-contact level measurement, but to operate safely in oil & gas, mining, and chemical processing applications, they must be paired with an Intrinsically Safe barrier.
The Migatron ZSB-409A delivers a compact, and reliable solution for enabling intrinsically safe ultrasonic sensing in the most demanding conditions.
Request a Quote today and learn how the ZSB-409A can safeguard your ultrasonic sensing applications.