A GUIDE TO THE USE OF ELECTRICAL EQUIPMENT

IN POTENTIALLY EXPLOSIVE ATMOSPHERES

Introduction
Potentially Explosive Atmospheres exist where there is a risk of explosion due to mixtures of gas/air, vapour/air, dust/air or other
flammable combinations.
In such areas there is a necessity to eliminate sources of ignition such as sparks, hot surfaces or static electricity which may ignite these
mixtures.
Where electrical equipment has to be used in these areas it must be so designed and constructed as to not create sources of ignition
capable of igniting these mixtures.
Before electrical equipment can be used in a potentially explosive atmosphere a representative sample has to be fully tested and certified
by an independent authority such as Baseefa 2001 in Europe or UL in the U.S.A.
This information is intended as a guide only and further expert guidance should be sought before placing into service, maintaining or
repairing any item of equipment in a Potentially Explosive Atmosphere.
Where comparisons are shown between, for example, European and North American practice this may be an approximation and
individual standards/codes of practice should be consulted for precise details.
MEDC have spent 25 years designing and manufacturing electrical equipment suitable for use in potentially explosive atmospheres. We
deal with all the major testing and certification authorities throughout the world and have a diverse range of internationally approved
products.

Area Classification
Process plants are divided into Zones (European and IEC method) or Divisions (North American method) according to the likelihood of
a potentially explosive atmosphere being present.
Note : North American legislation now allows Zones to be used to classify areas, where this practice is used it follows the IEC Zone
method.
European & IEC Classification Definition of zone or division North American Classification
Zone 0 (gases) An area in which an explosive mixture is Class I Division 1 (gases)
Zone 20 (dusts) continuously present or present for long periods Class II Division 1 (dusts)
Zone 1 (gases) An area in which an explosive mixture is Class I Division 1 (gases)
Zone 21 (dusts) likely to occur in normal operation Class II Division 1 (dusts)
Zone 2 (gases) An area in which an explosive mixture is not Class I Division 2 (gases)
Zone 22 (dusts) likely to occur in normal operation and if it Class II Division 2 (dusts)
occurs it will exist only for a short time Class III Division 1 (fibres)
Class III Division 2 (fibres)

Gas Groups (plus dusts and fibres)

There are two main gas groups, Group I – Mining only and Group II – Surface Industries
These categories are used in European and I.E.C. groupings.
Group I is concerned only with underground mining where methane and coal dust are present.
Group II gases occurring in surface industries, are sub-grouped according to their volatility. This enables electrical equipment to be
designed to less onerous tolerances if it is to be used with the least volatile gases.
Typical gas/material European/I.E.C. Gas Group North American Gas Group
Methane I -
Acetylene IIC A
Hydrogen IIC B
Ethylene IIB C
Propane IIA D
Metal dust - E
Coal dust - F
Grain dust - G

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Temperature
Hot surfaces can ignite explosive atmospheres. To guard against, this all Electrical Equipment intended for use in a potentially explosive
atmosphere is classified according to the maximum surface temperature it will reach in service. This temperature is normally based on
a surrounding ambient temperature of 40 degrees Centigrade (102 degrees Fahrenheit). This temperature can then be compared to the
ignition temperature of the gas(es) which may come into contact with the equipment and a judgement reached as to the suitability of the
equipment to be used in that area.
Many MEDC products are certified for use in ambient temperatures up to 55 degrees Centigrade, see individual data sheets for details.
Temperature Classification Maximum Surface Temperature
European/I.E.C. North American
T1 T1 450° C
T2 T2 300° C
T2A 280° C
T2B 260° C
T2C 230° C
T2D 215° C
T3 T3 200° C
T3A 180° C
T3B 165° C
T3C 160° C
T4 T4 135° C
T4A 120° C
T5 T5 100° C
T6 T6   85° C
e.g. Butane has an ignition temperature of 365 degrees Centigrade, equipment used in the vicinity of this gas would need a T rating of
T2 or higher.

Types of Electrical Equipment Suitable for use in Potentially Explosive Atmospheres

Different techniques are used to prevent electrical equipment from igniting explosive atmospheres. There are restrictions on where these
different types of equipment can be used as follows :
European IEC USA
Area of use Area of use Area of use
Designation Designation Designation
Standard Standard Standard
Flameproof Enclosure – An enclosure used to house electrical Zones 1 & 2 Zones 1 & 2 Class I
equipment, which when subjected to an internal explosion will not Divisions 1 & 2
ignite a surrounding explosive atmosphere. Exd Exd –
EN60079-1 IEC60079-1 UL1203
Intrinsic Safety – A technique whereby electrical energy is limited Zones 0, 1 & 2 Zones 1 & 2 Class I
such that any sparks or heat generated by electrical equipment is Divisions 1 & 2
sufficiently low as to not ignite an explosive atmosphere. Exi Exi –
EN60079-11 IEC60079-11 UL913
Increased Safety – This equipment is so designed as to eliminate Zones 1 & 2 Zones 1 & 2 –
sparks and hot surfaces capable of igniting an explosive Exe Exe –
atmosphere. EN60079-7 IEC60079-7 –
Purged and Pressurised – Electrical equipment is housed in an Zones 1 & 2 Zones 1 & 2 Class I
enclosure which is initially purged to remove any explosive mixture, Divisions 1 & 2
then pressurisedto prevent ingress of the surrounding atmosphere Exp Exp –
prior to energisation. EN60079-2 IEC60079-2 NFPA496
Encapsulation – A method of exclusion of the explosive atmosphere Zones 1 & 2 Zone 1 & 2 –
by fully encapsulating the electrical components in an approved Exm Exm –
material. EN60079-18 IEC60079-18 –
Oil Immersion – The electrical components are immersed in oil, Zone 1 & 2 Zones 1 & 2 Class I
thus excluding the explosive atmosphere from any sparks or hot Division 2
surfaces. EExo Exo –
EN50015 IEC60079-6 UL698
Powder Filling – Equipment is surrounded with a fine powder, such as Zones 1 & 2 Zones 1 & 2 –
quartz, which does not allow the surrounding atmosphere to come EExq Exq –
into contact with any sparks or hot surfaces. EN50017 IEC60079-5 –
Non-sparking – Sparking contacts are sealed against ingress of the Zone 2 Zone 2 –
surrounding atmosphere, hot surfaces are eliminated. Exn Exn –
EN60079-15 IEC60079-15 –
Selection, Installation and Maintenance of Electrical Equipment Intended for use in Potentially
Explosive Atmospheres
International and national standards are published giving details of requirements for the safe use of Electrical Equipment in Potentially
Explosive Atmospheres as follows :
International Europe U.S.A.
General Recommendations IEC60079-14 EN60079-14 N.E.C. Chapter 5
Classification of Hazardous Areas IEC60079-10 EN60079-10 N.E.C. Chapter 5
Inspection and Maintenance of Electrical Equipment IEC60079-17 EN60079-17 -
Requirements for Flameproof Enclosures IEC60079-14 EN60079-14 N.E.C. Chapter 5
Requirements for Intrinsically Safe Equipment IEC60079-14 EN60079-14 N.E.C. Chapter 5
Requirements for Increased Safety Equipment IEC60079-14 EN60079-14 N.E.C. Chapter 5
Requirements for Purged and Pressurised Equipment IEC60079-14 EN60079-14 N.E.C. Chapter 5
Requirements for Non-Sparking Equipment IEC60079-14 EN60079-14 -

MEDC advise that all Explosion-proof electrical equipment is maintained, by suitably trained personnel, in accordance with the Manufac-
turers’ recommendations.
Any spare parts used should be purchased from the original Manufacturer and repairs should be carried out by the Manufacturer or
under his supervision, in order that the item remains in conformance with the certification documents.

The Certification Process

All Electrical Equipment, intended for use in a Potentially Explosive Atmosphere, should be certified as suitable for such use.
The methods of obtaining certification differ in detail, see below, between each certifying body or group of bodies (e.g. CENELEC). Basically
this process consists of supplying a representative sample of the equipment along with a set of drawings to a recognised test/certification
body e.g. Baseefa 2001 who in turn test the equipment against a recognised Standard e.g. EN60079-14 and issue a Certificate. The
user of the equipment can then refer to this Certificate to enable him to safely put the item into service in a zone appropriate to the
Certification.

European Practice
ALL EQUIPMENT, BOTH ELECTRICAL AND MECHANICAL, INTENDED TO BE PUT INTO SERVICE WITHIN THE EEC HAS TO BE CERTIFIED
IN ACCORDANCE WITH THE ATEX DIRECTIVE.
It should be noted also that MECHANICAL equipment is covered by the ATEX Directive so for the first time items such as gearboxes will
have to carry ATEX certification.
The equipment coding signifying compliance with ATEX is as follows:
    II2G i.e.
     – Explosionproof in accordance with ATEX.
II – Group II surface industries.
2 – category 2 equipment (suitable for use in Zone 1) note: Category 1 is suitable for Zone 0.
Category 3 is suitable for Zone 2.
G – suitable for atmospheres containing gas (D is suitable for atmospheres containing dusts).
Equipment will be CE marked when certified to ATEX.

North American practice

Sample equipment and supporting documentation are submitted to the appropriate authority e.g.U.L., F.M., C.S.A.
The equipment is tested in accordance with relevant standards for explosion protection and also for general electrical
requirements e.g. light fittings.
After successful testing a listing is issued allowing the manufacturer to place the product on the market.
The product is marked with the certification details such as the gas groups A,B,C,D the area of use e.g. Class 1 Division 1.

Worldwide Certification
Most countries outside Europe or North America use the IEC Standards as a basis for their own national standards.
The Russian Federation certifies equipment to GOST ‘R’ standards, these closely follow CENELEC practice.
In Russia, certain products used in fire alarm systems may be required to carry the Russian fire approval (VNIIPO). Note
that not all MEDC products that have been certified to GOST ‘R’ are VNIIPO approved. Check specification on technical
data sheets before ordering.
Kazakhstan has a certification process (GOST ‘K’) where approval is normally based on compliance with CENELEC standards.
Certification in China is based on compliance with international standards such as CENELEC or UL.
There is a scheme in place which will when fully adopted allow for internationally recognised certification to become a reality,
this is the IEC EX SCHEME. This uses the IEC standards and IEC recognised test and certification bodies to issue mutually
recognised test reports and certificates. The scheme is in its infancy and its level of success cannot yet be measured.

Ingress Protection
2 digits are used to denote the level   IP
of ingress protection that a piece Solids Liquids
of apparatus enjoys:– 0 No protection. 0 No protection.
1 Protected against solid objects 1 Protected against vertically falling
up to 50mm, e.g. hands. drops of water.
2 Protected against solid objects 2 Protected against water spray up
up to 12mm, e.g. fingers. to 15 degrees from vertical.
3 Protected against solid objects 3 Protected against water spray up to
up to 2.5mm, e.g. tools. 60 degrees from vertical.
4 Protected against solid objects 4 Protected against water sprays from
over 1mm, e.g. wires. all directions.
5 Protected against dusts. (No 5 Protected against water jets from
harmful deposits). all directions.
6 Totally protected against 6 Protected against strong water jets from
dust. all directions, e.g. Offshore.
7 Protected against immersion between
15cm and 1m in depth.
8 Protected against long immersion
under pressure.

North American practice is to use NEMA standards to describe ingress protection, i.e.:
NEMA 3 is similar to IP 54
NEMA 4 is similar to IP 55
NEMA 4x is similar to IP 56
NEMA 6 is similar to IP 67

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