UNIT 6: Ex e Protection ‘Increased Safety ’

This unit will provide an understanding of the

principles of Ex e protection, the construction
requirements to EN/IEC 60079-7 and the installation
requirements to EN/IEC 60079-14.
 Increased Safety Ex e (or EEx e)

The explosion protection concept Increased Safety was invented in

Germany where it has been widely used for many years.
It is has become popular in the UK mainly because it has a number of
advantages for certain applications over the traditional flameproof method
of explosion protection.

America has traditionally relied on the use of explosion-proof enclosures

in hazardous locations, and the prospect of using an Increased Safety
enclosure, which is not designed to withstand an internal explosion, as an
alternative, has probably been viewed with a little trepidation.

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 Increased Safety Ex e (or EEx e)
v
This method of protection has a good safety
record and comparable with the other
methods of protection.

The letter ‘e’ which symbolizes this method

of protection is taken from the German
phrase Erhohte Sicherheit, which roughly
translated means ‘increased security’.

Typical applications are induction motors,

lighting fittings and junction boxes.

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 Increased Safety Ex e (or EEx e)

DEFINITION
‘A protection method in which increased measures are taken
to prevent the possibility of excessive HEAT, ARCS or
SPARKS occurring on internal or external parts of the
apparatus in normal operation’.

Zones of use: 1&2

AMBIENT TEMPERATURES
Increased Safety enclosures are normally designed for use
in ambient temperatures in the range -20 °C to +40 °C
unless otherwise marked.

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Increased Safety Ex e (or EEx e)

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 Increased Safety Ex e (or EEx e)

PRINCIPLE
The safe operation of Increased Safety apparatus is dependent on the
prevention of any source of ignition, i.e. excessive surface temperatures,
arcs or sparks, which might otherwise be produced by internal or external
parts of the apparatus. Special design features are, therefore,
incorporated in the apparatus by the manufacturer anda re as follows.

• 1) Mechanically strong enclosure resistant to impact - tested to 4 or 7

joules impact energy depending on application.

• 2) Ingress protection against solid objects and water - at least IP 54.

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 Increased Safety Ex e (or EEx e)

• 3) Terminals manufactured from high quality insulation material.

• 4) Specified creepage and clearances incorporated in design of

terminals.

• 5) Terminal locking devices to ensure conductors remain secure in

service.

• 6) Certified de-rating of terminals.

• 7) Terminal population of enclosure limited by circuit design.

• 8) Close excess current circuit protection.

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 Increased Safety Ex e (or EEx e)

INCREASED SAFETY TERMINALS

The terminals installed in an Increased Safety enclosure
must be ‘component certified’ terminals.
They will be manufactured from good quality materials such
as Melamine, Polyamide and, for special applications,
Ceramic.

These materials, which have good thermal stability, have

been subjected to a ‘Comparative Tracking Index (CTI)’ test
to determine their resistance to tracking.

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 Increased Safety Ex e (or EEx e)

The following definitions are relevant:

• Clearance distance: The shortest distance through air between two
conductors.
• Creepage distance: The shortest distance between two conductors along
the surface of an insulator.
• Tracking: The leakage current which passes across the contaminated
surface of an insulator between live terminals, or live terminals and earth.
• Comparative Tracking Index: The numerical value of maximum voltage, in
volts at which an insulation material withstands e.g., 100 drops of
electrolyte (usually ammonium chloride solution in distilled water) without
tracking.

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 Increased Safety Ex e (or EEx e)

Creepage and Clearance Distances

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 Increased Safety Ex e (or EEx e)

Creepage and Clearance Distances

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 Increased Safety Ex e (or EEx e)

Creepage and Clearance Distances

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 Increased Safety Ex e (or EEx e)

INCREASED SAFETY TERMINALS

Creepage distances relative to voltage and grade of insulation
The following table shows the creepage distances relative to the grade
of material and applied voltage.

Minimum creepage (mm)

Rated Minimum
Voltage Insulation Grade to IEC 112 Clearance
(V) (mm)
a b c d

33 3 3 3 3 -

66 3 4 5 6 3

275 6 8 10 12 5

418 8 10 12 15 6

550 10 12 15 18 8

726 12 16 20 25 10

1100 20 25 30 36 14

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 Increased Safety Ex e (or EEx e)

INCREASED SAFETY TERMINALS

Increased Safety terminal types and ratings
The terminals are de-rated so that the maximum current for
Increased Safety applications is nearly half that for standard
industrial applications.
This de-rating, along with other considerations, ensures that
internal and external surface temperatures are kept within
prescribed limits.

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Increased Safety Ex e (or EEx e)

INCREASED SAFETY TERMINALS

The table below also shows the maximum conductor size for each
terminal type.

Increased Safety
Conductor Industrial maximum current
Terminal type maximum current
size (amps)
(amps)

SAK 2.5 2.5 15 27

SAK 4 4 21 36

SAK 6 6 26 47

SAK 10 10 37 65

SAK 16 16 47 87

SAK 35 35 75 145

SAK 70 70 114 220

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Increased Safety Ex e (or EEx e)

INCREASED SAFETY TERMINALS

Terminal locking device
It is essential that conductors are
securely connected in the terminals to
prevent sparks occurring as a result of
loose connections.

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 Increased Safety Ex e (or EEx e)

INCREASED SAFETY TERMINALS

Estimation of terminal population
The number of terminals which can be installed in a given size of
enclosure is limited.
Several methods have been developed by manufacturers for this purpose.

• Enclosure factor: A method used in apparatus manufactured to BS

4683 Part 4 in which the terminal content is assessed by dividing the
‘enclosure factor’ by the certified current rating of a given terminal.

• Load limit: Similar to ‘enclosure factor’ but used only on apparatus

manufactured to BS 5501 Part 6.

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 Increased Safety Ex e (or EEx e)

• Kelvin rating: Normally used for high current applications and apparatus
manufactured to BS 4683 Part 4 and BS 5501 Part 6. In this method,
enclosures and terminals are assigned a temperature rating. Enclosures will
normally be limited to a temperature rise of 40K for a T6 temperature rating, but
the temperature for the terminals will be dependent on their type, rated current,
size of associated conductor, and the size of enclosure in which they are
installed. This involves the use of tables which are provided by the
manufacturer. Once the terminal ‘K’ rating has been established, it is divided
into the ‘K’ rating for the enclosure to give the number of terminals of one type
which may be installed.

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 Increased Safety Ex e (or EEx e)

• Max dissipated power: This is a method which will replace

the current ‘load limit’ method and applies to apparatus
manufactured to BS 5501Part 6 and BS EN50 019. In this
method, enclosures are assigned a ‘watts dissipation’
rating, but the rating of the terminals is determined by use
of a unique table (provided by the manufacturer) for the
enclosure. This table provides the ‘watts dissipation’ of the
terminal through consideration of conductor size and load
current. The terminal content is determined by dividing the
‘watts dissipation’ value for the terminal into that for the
enclosure.

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 Increased Safety Ex e (or EEx e)

TERMINAL ASSEMBLIES

1. Mounting rail
2. Terminals - certified
components
3. End plate
4. End bracket
5. Distance sleeve
6. Partition
7. Copper cross-connection
8. Zinc plated screw
9. Copper cross-connection
10. Copper cross-connection
Component approved terminal group

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Increased Safety Ex e (or EEx e)

TERMINAL ASSEMBLIES

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 Increased Safety Ex e (or EEx e)

INSTALLATION, INSPECTION AND MAINTENANCE

It is essential that Increased Safety enclosures are installed and maintained in
accordance with the relevant Standards and Codes of Practice in order to comply
with the Certification. The following list specifies the main points:

• Enclosure content should not be modified without consulting the manufacturer.

• Only components specifically approved should be fitted in the enclosure.

• All terminal screws, used and unused, should be tightened down.

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 Increased Safety Ex e (or EEx e)

INSTALLATION, INSPECTION AND MAINTENANCE

• CONDUCTOR INSULATION SHOULD EXTEND TO WITHIN 1 MM FROM THE METAL THROAT

OF THE TERMINAL.

• PARTITIONS SHOULD BE FITTED AT EITHER SIDE OF TERMINAL LINKING ASSEMBLIES.

• ONLY ONE CONDUCTOR SHOULD BE FITTED TO EACH TERMINAL SIDE.

• AN ADDITIONAL SINGLE CONDUCTOR, MIN 1.0 MM2, MAY BE CONNECTED WITHIN THE
SAME TERMINAL WAY WHEN AN INSULATED COMB IS USED.

• ONLY THE CONDUCTORS FROM EACH CABLE ENTRY SHALL BE LOOMED TOGETHER.

• THE INSULATION OF CABLES SHALL BE SUITABLE FOR USE AT LEAST 80°C FOR A T5
TEMPERATURE CLASS.

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 Increased Safety Ex e (or EEx e)

INSTALLATION, INSPECTION AND MAINTENANCE

• THE INDIVIDUAL EARTH CONTINUITY PLATES WITHIN PLASTIC ENCLOSURES MUST BE

BONDED TOGETHER AND LOCKNUTS USED TO SECURE GLANDS TO THE CONTINUITY

PLATES. FOR CLEARANCE HOLES, SERRATED METAL WASHERS MUST BE USED

BETWEEN LOCKNUTS AND THE GLANDPLATE.

• WHEN INTRINSIC AND INCREASED SAFETY CIRCUITS OCCUPY THE SAME ENCLOSURE
THE TWO TYPES OF CIRCUIT MUST HAVE AT LEAST 50 MM CLEARANCE BETWEEN
THEM.

• THERE MUST BE ADEQUATE CLEARANCE BETWEEN ADJACENT ENCLOSURES TO ALLOW

PROPER INSTALLATION OF CABLES AND GLANDS.

• ALL UNUSED CABLE ENTRIES SHOULD BE CLOSED USING SUITABLE PLUGS.

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 Increased Safety Ex e (or EEx e)

INSTALLATION, INSPECTION AND MAINTENANCE

• THE SCHEDULE OF THE APPROPRIATE CERTIFICATE SHOULD BE CONSULTED BEFORE

CABLE ENTRY HOLES ARE DRILLED.

• CABLE GLANDS OR CONDUIT ENTRIES MUST MAINTAIN THE MINIMUM INGRESS

PROTECTION OF

IP 54.

• ALL LID AND GLAND PLATE BOLTS MUST BE FULLY TIGHTENED AFTER INSTALLATION.

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 Increased Safety Ex e (or EEx e)

INCREASED SAFETY EEX e MOTORS

THESE MOTORS ARE SIMILAR IN APPEARANCE TO STANDARD INDUSTRIAL MOTORS AND
INSPECTION OF THE CERTIFICATION/RATING PLATE IS USUALLY NECESSARY TO IDENTIFY

THEM.

THESE MOTORS ARE NOT DESIGNED TO WITHSTAND AN INTERNAL EXPLOSION AND

HENCE HAVE SPECIAL DESIGN FEATURES TO PREVENT ARCS, SPARKS AND EXCESSIVE

SURFACE TEMPERATURES OCCURRING BOTH INTERNALLY AND EXTERNALLY.

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 Increased Safety Ex e (or EEx e)

INCREASED SAFETY EEX e MOTORS

THE PRINCIPAL DESIGN FEATURES ARE:
SPECIAL ATTENTION TO AIR GAP CONCENTRICITY AND CLEARANCE OF ALL ROTATING
PARTS

IMPACT TESTING OF MOTOR FRAME

TEMPERATURE RISE 10 °C LOWER THAN NORMAL
T2 OR T3 SURFACE TEMPERATURE LIMITATION
COMPLIANCE WITH Te CHARACTERISTIC
SPECIAL TERMINAL BLOCK WITH SPECIFIC CREEPAGE / CLEARANCE DISTANCES AND
LOCKING DEVICES ON TERMINALS

MINIMUM INGRESS PROTECTION TO IP54

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 Increased Safety Ex e (or EEx e)

INCREASED SAFETY EEX e MOTORS

UNDER STALL (LOCKED ROTOR) CONDITIONS, THE ROTOR SURFACE TEMPERATURE WILL
NORMALLY INCREASE FASTER THAN THAT OF THE STATOR WINDINGS, AND HENCE, THE T
RATING APPLIES TO BOTH INTERNAL AND EXTERNAL SURFACE TEMPERATURES.

UNDER FAULT CONDITIONS, THE MOTOR MUST TRIP WITHIN THE Te TIME SPECIFIED ON
THE MOTOR DATA PLATE.

INCREASED SAFETY MOTORS ARE INTENDED FOR CONTINUOUS DUTY ONLY, I.E. THEY ARE
UNSUITABLE FOR APPLICATIONS WHICH REQUIRE FREQUENT STOPPING AND STARTING

AND/OR LONG RUN-UP TIMES.

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 Increased Safety Ex e (or EEx e)

tE TIME
tE TIME IS DEFINED AS ‘THE TIME TAKEN TO
REACH THE LIMITING TEMPERATURE FROM THE

TEMPERATURE REACHED IN NORMAL SERVICE

WHEN CARRYING THE STARTING CURRENT Ia AT

MAXIMUM AMBIENT TEMPERATURE.

IN THE GRAPH SHOWN, ‘OA’ REPRESENTS THE

MAXIMUM AMBIENT TEMPERATURE AND ‘OB’ THE
TEMPERATURE REACHED AT MAXIMUM RATED

CURRENT

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Increased Safety Ex e (or EEx e)

IF THE ROTOR LOCKS AS A RESULT OF A FAULT,

THE TEMPERATURE WILL RISE RAPIDLY TOWARDS

‘C’ AS SHOWN IN PART 2 OF THE GRAPH, WHICH IS

LESS THAN THE T RATING OF THE MOTOR.
THE TIME TAKEN TO REACH ‘C’ FROM ‘B’ IS
KNOWN AS THE tE TIME, AND DURING FAULT

CONDITIONS THE THERMAL OVERLOAD DEVICE IN

THE MOTOR STARTER MUST TRIP OUT THE MOTOR

WITHIN THIS TIME.

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Increased Safety Ex e (or EEx e)

Limiting Temperature
Temperature limited either by
selected T-Rating or Limit for Class
of Winding Insulating Material

A = maximum ambient
temperature;
B = maximum temperature at
rated current;
C = limiting temperature;
 = temperature;
(1) = temperature rise at rated
current;
(2) = temperature rise during
locked rotor test;
tE = time from maximum
temperature (B) at rated current to
limiting temperature (C).

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Increased Safety Ex e (or EEx e)

TRIPPING CHARACTERISTIC OF THERMAL

OVERLOAD

THE THERMAL OVERLOAD WILL BE SELECTED

FOR SUITABILITY ACCORDING TO ITS

TRIPPING CHARACTERISTIC. THE tE TIME

AND Ia/In CURRENT RATIO ARE INFLUENTIAL
IN THE SELECTION OF THE DEVICE AND ARE

MARKED ON THE MOTOR NAMEPLATE.

IN = rated current of motor;

IA = locked rotor current of motor

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