Flameproof Equipment CH 06-11 April 01

CHAPTER 6
FLAMEPROOF EQUIPMENT, Ex d
6.1 The flameproof principle
Electrical equipment which may ignite a flammable

gas is placed inside an enclosure which is able to
withstand the pressure generated by an internal
explosion and which prevents transmission of the
flame to an external flammable atmosphere.
The letter ‘d’ in the abbreviation for flameproof comes from the German; ‘ druckfeste Kapsulung’.
Flameproof equipment can be used in zone 1 (ATEX ‘Category 2’) provided it is of an appropriate
apparatus group and temperature class. In North America, the concept is known as ‘explosionproof’.
Note that flameproof equipment is not ‘fireproof’: Ex d equipment is able to cope with an internal flame
lasting just a few milliseconds, but is not designed to withstand an external fire.
6.2 Applications
 The enclosure provides the protection rather than the

equipment inside
 Some limitations, e.g.
 internal layout must consider pressure piling
 battery packs must be intrinsically safe
 Wide range of applications, e.g.
 junction boxes
 switches
 luminaires
 motors
 instruments
Flameproof (Ex d) and increased safety (Ex e) are often alternative methods of protection for many items
of equipment, though Ex e cannot include switches and instrumentation. The method of protection chosen
depends on design and cost considerations.
6.3 Certification
 BS 229:1959
 superseded 1971 but much still in use
 has ‘FLP’ rather than ‘EEx d’ marking
 usually no temperature class
 BS 4683:1971
 EN 50018:1977 (BS 5501)
 European ‘first edition’
 EN 50018:2000
 European ‘third edition’
 covers most EHSRs of ATEX 94/9/EC Directive
 IEC 60079-1:1990 + A1 & A2
 FM 3615, FM3618, UL1203, UL2279:1 (USA)
Chapter 6, page 1 of 8
©Sira April 2001
BS 229 was the first British Standard for flameproof equipment. This equipment was not required to have
its temperature rise measured so usually has no temperature class. This equipment may be repaired with
new parts (if available), but complete items should ideally be replaced with an equivalent to the most
modern standard. It is intended that this equipment will eventually be withdrawn. It is distinguished by
the ‘FLP’ logo.
BS 4683 equipment is similar to that constructed to BS 5501:Part 5/EN 50 018:1977.
EN 50 018:1977 is one of the current standards for flameproof equipment but will be withdrawn on 30th
June 2003.
EN 50018:1994 is the latest standard and will coexist with the 1977 standard until 30th June 2003.
6.4 How Ex d equipment works
Perfect seal Gaps permitted

- impractical - up to a maximum
NOTE: the enclosure does not require a gap to relieve

pressure - the ideal is no gap
The electrical equipment is housed in a specially constructed enclosure which does not permit an internal
explosion to ignite the surrounding atmosphere. A flameproof enclosure is built strong enough to resist the
internal forces of an exploding gas, and with gaps narrow enough to cool (reduce the energy) of the
exploding gases so that they cannot ignite a flammable gas outside the enclosure. Tests show that even if
a small gap is present between the cover and lid, the internal flame is quenched provided the gap is not too
wide. Thus, a gap is allowed between mating surfaces up to a specified maximum. Flameproof
enclosures do not rely on the maintenance of a gap to relieve the pressure - no gap at all gives the biggest
safety margin.
The maintenance of gaps well below the maximum permissible is important - in a Zone 1 area gas may be
entering and be ignited and expelled at various times in its life. No intentional gap has to be left and
joints should be fitted as close as possible. No intervening loose or perishable packing is allowed in gaps
except permitted greases or gaskets/O-rings supplied by the manufacturer.
Corrosion of the mating surfaces, and physical damage through careless handling when the housing is
opened for inspection and repair, can increase the gap dimensions of jointed surfaces above the maximum
safe gap and destroy the flameproof characteristics.
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6.5 Types of flamepath
In flameproof equipment, all joints between compartments, or between the inside of the enclosure and the
outside, are made from the above joint types, either singly or in combination.
t6.6 The mechanism of quenching
Flamepaths rely on at least two mechanisms to prevent flame transmission to the outside:
1 Expanding and cooling - as the hot gases decompress, they cool - least significant with IIC gases
2 Mixing (‘entrainment’) and cooling - as the hot gases escape from the flamepath they rapidly mix
with the unburned gas and cool - most significant for IIC gases
From 2, it follows that obstructing the flamepath (with paint, tape or other obstructions) could make the
flame quenching less effective, particularly with IIC gases.
©Sira April 2001
6.7 Typical allowed gaps
Max. gap (mm)

IIA 0.4
IIB 0.2
IIC 0.1
IIC gases are best at burning through gaps
The maximum permitted gaps are well below the maximum gap that would still quench the flame, so the
values in the table include a large safety margin.
6.8 Obstruction of flamepaths
 EN 60079-14 and BS 5345 require the following

clearance distances for flanged joints only:
 Group IIA gases 10 mm
 Group IIB gases 30 mm
 Group IIC gases 40 mm
 IIA gases: mainly cooling by expansion

 IIC gases: mainly cooling by mixing
Ex d equipment with flanges must be installed such that obstructions such as other equipment, walls, etc.
are outside the prescribed distances.
6.9 Obstruction of flamepaths: tape
‘Denso’ tape reduces effectiveness of flamepaths

 Effect is most critical for IIC gases, least for IIA
 One layer only allowed for IIA gases
 BS 5345 allows use with IIB gases, EN 60079-14 does not
Gas group Allowed MESG MESG

gap (no tape) (with tape)
IIA 0.4mm 0.99mm 0.89mm
IIB 0.2mm 0.69mm 0.28mm
IIC 0.1mm 0.28mm 0.05mm
Tape around the flamepath has been shown by test to reduce the effectiveness of the flamepath’s
quenching action. This effect applies most to IIC gases, least to IIA gases. The use of an approved non-
hardening tape (e.g. ‘Denso’ tape) around the joint may be used in certain conditions. BS 5345 and
EN 60079-14 differ slightly in their recommendations.
 Both codes allow 1 layer of tape with IIA, IIB or IIC equipment used with IIA gases.
 BS 5345 also allows 1 layer of tape with IIB or IIC equipment used with IIB gases after “seeking
expert advice”. The advice given for Group IIB equipment might be to check that the maximum gap
present in the equipment is not more than 0.1mm (about half the normal maximum allowable gap). If
©Sira April 2001
the relevant company code of practice uses this interpretation, 1 layer of approved non-hardening tape
may be used.
 Both codes agree that tape should never be used on equipment exposed to IIC gases.
It is best to use tape in accordance with EN 60079-14: one layer only where IIA gases are involved,
otherwise none permitted. [Note that it is the apparatus group of the gas that is considered, not that of the
apparatus itself.]
6.10 Obstruction of flamepaths: paint
 EN 60079-14 states that paint should be

kept out of the flamepath
 Good practice dictates that flamepath

gaps should not be painted over
BS 5345 and EN 60079-14 both state that paint should not be allowed to flow between the faces of a
flamepath but do not give guidance on painting over the outside of the gap for weatherproofing reasons.
However, from the guidance for tape, it is clear that paint will have the same detrimental effect and we
may conclude that paint should not be applied over the gap.
6.11 Obstruction of flamepaths: gaskets and O-rings
 The user should not add gaskets or O-

rings if not already present
 An IP washer is allowed when installing a

gland
(5 threads and 8 mm engagement required)
Weatherproofing should ideally be designed into equipment by the manufacturer, so that any effects on
‘flameproofness’ are taken into account in the testing and certification. Temporary measures by the user
to improve weatherproofing by fitting gaskets or O-rings are not allowed, with the exception that it is
permitted to fit an ingress protection washer when installing a gland, provided the required thread length
(currently 8 mm/5 threads) may still be engaged. An earthing tag may also be fitted subject to thread
engagement length.
Note that glands and stoppers for flameproof equipment must be certified. If apertures in a flameproof
enclosure are not used, they must be closed so that the flameproof properties are maintained. The closing
devices shall either be capable of being fitted and removed from the inside of the enclosure only or, shall
be fixed by means of so-called ‘special fasteners’ (essentially tamper-proof devices). This is dealt with
more fully in the chapter on cable entry.
©Sira April 2001
6.12 Grease
 Grease is permitted but must be

 non-flammable
 non-setting
 Examples of greases which meet these requirements:
 Rocol ASP
 ‘Hylomar’ - made by Marston Lubricants
 ‘Coppergrease’ - made by Chemodex
 ‘Kopr-Kote’ - made by Jet-Lube
 Moly-Paul Anti-Seize Compound manufactured by K.S.Paul
 Coppergrease manufactured by Chemodex Products
 TS-6 Plastic Jointing Compound manufactured by Vecom
 Ensis Compound 356 manufactured by Shel
 Any light petroleum or silicone grease
The above substances are non-setting and may be used for corrosion prevention and also inhibiting ingress
of moisture without affecting the safety of flameproof enclosures, provided that the apparatus concerned
complies, after the application, with the requirements of the certification documents for that apparatus.
The list is not exhaustive.
Note: Gas detectors can be poisoned by the presence of small quantities of silicones. Extreme care
should be taken to ensure their integrity is not jeopardised by the use of silicone greases on an
installation. Finally, note that as many of these compounds are insulators it is possible that earth
continuity may be interrupted.
6.13 Greasing bolts
Excessive grease in
blind bolt hole
causes bolt to
‘bottom out’
grease
casing may crack

due to
hydraulic
pressure
Take care when greasing cover bolts as the holes they locate into are often ‘blind’ in flameproof
equipment. Excessive grease will fill the hole and cause the bolt to bottom out or even, with excessive
torque, crack the casing.
6.14 Electrical protection
It must not be forgotten that, although a short-circuit within a flameproof enclosure is permissible, it is not
proof against the effects of a huge current which is not quickly reduced by circuit protection. In a low
voltage fault, power up to 20 MVA or more can be produced by an internal short-circuit; this is
enormously larger than the forces produced by a box full of flammable gas. It is important, therefore, that
©Sira April 2001
all circuits supplying flameproof (or other explosion-protected equipment) be equipped with electrical
protection that cuts off the power in as short a time as possible.
Fusing normally reduces the energy ‘let through’ to a smaller level than a circuit breaker as it interrupts
the fault current within the first quarter of a cycle, so reducing heat and mechanical damage within the
enclosure. There have been instances when insulation has been set on fire and brass glands burned through
by fault current which may attain values of thousands of amps.
6.15 Pressure piling
An explosion in one …. pre-pressurises gas

part of the enclosure.... in the other part….
....so the resulting explosion is more severe because the flame is igniting a gas/air mixture which is
already pre-pressurised and burns more quickly through it.
Motors and other large enclosures have relatively large spaces internally, in addition to passageways
between terminal boxes and the ends of the machine and the passageways formed by the rotor/stator gap.
This division of an enclosure into connected compartments will bring the danger of pressure piling. The
rotor-stator gap is one important passageway where careful attention must be given to the restriction of
clearances. When skimming rotors during overhaul, care must be taken not to increase the rotor/stator gap
to larger than design figures. Manufacturer's drawings and advice are required before this is carried out, as
with any repair which exceeds the simple replacement of like with like.
6.16 Stopper boxes
If no stopper boxes,
pressure increases down
conduit - may even detonate
Must have stopper boxes
Care should be exercised when fitting conduit to flameproof enclosures. The codes of practice require
that a stopper box is fitted at the enclosure wall (BS 5345) or within 450 mm (EN 60079-14) of the
enclosure. Failure to fit this would cause pressure piling down the conduit with the pressure increasing
progressively. This causes the flame to speed up and could even lead to a detonation where the unburned
gas ahead of the flame gets so hot (due to compression and radiated heat) that it reaches its auto-ignition
temperature and explodes with great speed and consequential high pressure.
©Sira April 2001
6.17 Component-certified Ex d enclosures
A typical schedule of limitations:

 use only certified glands and stoppers
 do not drill additional holes
 no fans or motors
 maximum power dissipation 100 W
 do not locate internal sub-assemblies within 50mm of the enclosure wall
 no batteries unless intrinsically safe
 at least 20% of any cross section to remain clear to prevent pressure
When purchasing an empty certified Ex d enclosure, it will come with a set of limitations as to what can
and cannot be installed. It is tempting to think that an Ex d enclosure is so strong that there will be no
limitations on what may be installed inside. This is not the case and, while the limitations are not very
restrictive, they must be complied with.
 The Ex d concept only permits certified glands and stoppers as they need to be explosion-proof
 Additional holes should not be drilled as thread form, quality of fit, wall thickness, etc. are all critical
 Fans and motors cause gas movement that may increase the explosion pressure
 A power limit is necessary to define the temperature class
 An ‘exclusion zone’ around the edge prevents hot spots on the outside casing
 Batteries cannot be isolated before opening and can spark incendively when the cover is removed
unless they are intrinsically safe
 Excessive crowding, particularly enclosures within the main enclosure, can lead to pressure piling
©Sira April 2001
CHAPTER 7
INTRINSIC SAFETY, Ex i
7.1 The principles of intrinsic safety
Principle - ‘safe spark’ concept:

Limit spark energy to a non-incendive level;
Limit the temperature rise of components.
Considers fault conditions:
- safe with indefinite minor faults & 2 major faults for EEx ia
- safe with indefinite minor faults and 1 major fault for EEx ib
Typically,
- used for instrumentation
- low power equipment (usually less than 1.3W)
Intrinsic safety is a technique where the electrical energy available in any spark which can occur in the
hazardous area will be non-incendive. Put simply, intrinsic safety is the ‘safe spark’ concept. The
generally used values for the spark ignition energies (from EN 50020:1994 clause 6.3.3) are as follows
and impose a severe restriction on the design of equipment:
Group IIC (hydrogen/air) limited to…. 40 µJ

Group IIB (ethylene/air) limited to…. 160 µJ
Group IIA (propane/air) limited to…. 320 µJ
The above are measures of the discharge of energy stored in, for instance, an inductor when discharging
into a single spark. [The sparks produced by a resistive circuit are sufficiently different in nature to
produce figures of 0.5-1 watt and above without risk of ignition.] The IEC and European standards apply
a safety factor of 2.25 to these energy values, whereas FM 3610, for example, only requires a safety factor
of 1.5.
Intrinsically safe apparatus and systems are therefore designed such that a spark, even if produced
accidentally (by a conductor coming loose or a PCB track breaking, for example), will not cause ignition
of the gas. It can be seen from the above ignition energies, however, that a piece of apparatus designed
for IIA gases, and therefore limited to a spark energy of well below 320 µJ, would be inappropriate for IIB
or IIC gases. Intrinsically safe equipment is always sub-grouped and should be selected according to the
gas group of the hazard gas. For practical reasons, I.S. apparatus is usually given a T4 temperature class.
Intrinsically safe equipment is either ‘ia’ or ‘ib’. The differences are as follows:
 ia: still safe with 2 prescribed faults - can be used in zones 0, 1 and 2 (Category 1 equipment)
 ib: still safe with 1 prescribed fault - can be used in zones 1 and 2 (Category 2 equipment)
©Sira April 2001
7.2 Certification
UK
BS 1259 – until 1969
Europe
EN 50020:1977 (‘first edition’) + EN 50014:1977
EN 50020:1994 (‘second edition’) + EN 50014:1997
Other
IEC 60079-11:1999 + IEC 60079-0:2000
FM3610 + FM3600
UL 913
CSA-157
The following standards deal with intrinsically safe equipment:

1 BS 1259 – certificates issued by HMFI up to 1969 – in general, equipment certified to this
standard should be replaced with more modern equipment. Hot surface ignition problem was not
addressed.
2 EN 50020:1977 – ‘first edition’ standard, applied in conjunction with EN 50014:1977 (general
requirements)
3 EN 50020:1994 – ‘second edition’ standard, applied in conjunction with EN 50014:1997 (general
requirements) and covers most of the EHSRs of the ATEX 94/9/EC Directive
4 IEC 60079-11:1999 – technically identical to EN 50020:1994 – applied in conjunction with
IEC 60079-0:1998 (general requirements)
5 FM 3610 (plus FM 3600 - general requirements) – for listing in the USA
6 UL 913 – for listing in the USA
7 CSA-157 – Canada has now joined the IECEx scheme and it is likely that the IEC standards will
replace Canadian national standards.
There are significant differences between the first and second editions of EN 50020, notably that the
second edition allows less capacitance at certain voltages and requires more rigorous testing of cells as
well as a large number of differences in detail. Generally, the second edition is easier to work to as it fills
in the ‘grey’ areas in the first edition. A third edition is under discussion.
Generally, intrinsically safe equipment seeking certification in more than one region will probably be
acceptable against a variety of standards with some extra assessment and testing required. Some specific
points to note are as follows:
1 The so-called “IECEx Scheme” is in its infancy (the first certificate was issued in late 2000) and
will, eventually, do away with the different standards throughout the world. There are various
reasons why this will not happen soon: within Europe, for example, the ATEX Directives run
counter to the global certification philosophy
2 The USA is running two sets of standards side-by-side: the newer set similar to the IEC, the older
set having significant differences
3 When equipment is already certified to the older standards in North America and the manufacturer
requires certification for Europe, there may be problems with the fact that the European standards
require a larger safety factor on energy
4 Europe-certified equipment may fall foul of the more onerous requirements for non-metallic
enclosure material and ingress protection in the older standards used for in North America
5 Australia has adopted the IEC standards as its national standards
6 The European Standard for I.S. systems is EN 50 039:1982; a new edition is expected shortly
©Sira April 2001
7.3 Battery-powered equipment
Only use the battery type specified on the label

The wrong type may:
 overheat/explode/leak under short-circuit conditions
 fail the external separation requirements between + and
-
 have insufficient internal resistance to limit current to a
safe level (sometimes relied upon)
The wrong type will:
Apparatus such as test meters, data loggers, torches, etc, which are battery-powered should only be used
with the batteries specified in the certificate - usually, this information is also on the battery compartment
cover. Under fault conditions, the wrong batteries may become too hot, deliver too much current, leak or
fail to meet the standard in other ways. Rechargeable batteries and some disposable batteries are capable
of dangerously high currents if short-circuited and can only be used in I.S. apparatus in conjunction with a
current-limiting resistor or similar device.
Unless the apparatus certificate says otherwise, rechargeable batteries should only be recharged in the
non-hazardous area. Also, the output of the charger must be checked against the certificate - excessive
voltage may damage safety-critical components in the apparatus and render it unsafe for use in the
hazardous area.
7.4 Fixed equipment – a typical intrinsically safe system
I.S. system
Barrier/isolator
[EEx ia] IIB
Instrument
Power supply
EEx ib IIC T4
(250V max)
I.S. circuit
The term for the usual fixed installation is an ‘Intrinsically Safe System’ and typically consists of at least
two items of equipment, one in the hazardous area and the other in the non-hazardous area, connected by
cable. The system coding is always the least favourable coding of any part of the system. For example,
consider the system of a barrier and an instrument above.
In this case, the coding of the system is EEx ib IIB T4 and the instrument can not be used with IIC gases
as the barrier only allows IIB. Note the square brackets in the barrier coding which indicates that the
barrier itself cannot be located in a hazardous area without further protection. [If, for operational reasons
the barrier must installed in the hazardous area and not in the control room, then the commonest solution
is to install it in a flameproof enclosure.]
Note 1: The power supply and associated apparatus may be combined into one item, which must
then be certified.
Note 2: ‘Barriers’ and ‘isolators are two types of ‘associated apparatus’ – see section 7.8.
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7.5 Associated apparatus
Two main types: Current (mA)

- zener barriers 5000
- galvanic isolators Graph of ignition current
Function: against voltage for hydrogen.
- to limit the current into the Permitted current is 2/3 of

hazardous area to a safe level the ignition current.
at the given voltage

- prevent mains breakthrough
180
12 28 Voltage
Intrinsic safety is a system concept so it is necessary to consider the safety of each item of equipment in
the loop. Equipment located in both safe and hazardous areas must be considered and the interaction
between the pieces of equipment analysed. Using a safety ‘interface’ between the safe area equipment and
the hazardous area removes the necessity for detailed consideration of the safe area equipment, which
need not be certified.
There are basically two types of interfaces, known as ‘associated apparatus’:

Zener barriers - these have a relatively simple network of fuses, resistors and zener or ordinary
diodes to clamp the voltage and limit the current;
Galvanic isolators - these provide galvanic isolation between the hazardous and safe areas using
transformers, opto-isolators or relays.
The barrier or isolator must be able to limit the voltage and current even when the safe area power supply
malfunctions. Usually, such devices are certified up to a maximum input voltage (U m,) of 250 Vrms
relative to earth; this is more or less the only restriction on the power supply. The barrier or isolator
always defines the maximum voltage that can be supplied to the hazardous area, but some do not state the
current directly: instead, a resistance is quoted and I o must be calculated from Uo/R.
Most intrinsically safe systems use proprietary barriers and isolators, from manufacturers such as MTL,
Pepperl & Fuchs, Stahl, Turck, Elcon and others. These are invariably certified and have the advantage
that equipment upstream (e.g. instrument transformer, computer, etc.) need not be certified. However, a
manufacturer of an intrinsically safe instrument may decide to combine the power supply and signal
processing circuitry with suitable interface circuitry, in which case the entire equipment requires
certification (though the certifying process will concentrate on the relatively simple voltage/current
limiting circuitry protecting the outputs to the hazardous area terminals).
Marking: associated apparatus is indicated by square brackets, for example:

[EEx ia] IIC
©Sira April 2001
7.6 Zener barriers
current-limiting fuse
resistor
zener diodes
I.S. earth required
There are two basic safety requirements of a shunt-diode safety barrier.

1 Prevent potential differences within the circuit from becoming dangerous.
2 Provide a low resistance high integrity return path for any fault current which might originate in
the safe area, thus avoiding dangerous voltages and currents within the hazardous area.
1) Refer to diagram above. The right hand terminals are connected to normal industrial apparatus in the
non-hazardous area. The fuse and zener diodes are chosen so that even if mains voltage, U m, is applied to
these terminals on failure of the industrial apparatus then the zener diodes will hold the barrier voltage
down until the fuse blows. The final resistor defines the barrier output current. The resistors used are of a
type and rating such that they are not considered subject to short circuit faults and the zener diodes are
subjected to special tests after which their possible open circuit failure is discounted. The entire device is
usually encapsulated so that if the internal fuse blows replacement of the device is necessary. [Some
barriers incorporate a replaceable external fuse to protect the internal fuse.]
2) The diagram below illustrates this basic principle and how the barrier protects the hazardous area
circuit against excessive voltage should a high voltage appear on the non-hazardous area terminals, caused
in this illustration by a metal spike being hammered through a mains cable and then the supply cable to
the barrier. The low resistance ( 1 ohm) between point X' and X reduces potential differences
experienced to an acceptable level and provides a route for the fault current, thus blowing the fuse.
©Sira April 2001
7.7 Barrier earthing
Hazardous area Instrument transformer
zener barrier
Barrier
earth
(<1 ohm,
2 x 1.5mm
cables min.
It is important that the barrier earth provides a low resistance path back to the source of supply. In case of
mains breakthrough, this arrangement prevents an elevated voltage from reaching the hazardous area.
7.8 Galvanic isolators
resistor fuse ac/dc converter
= ~
~ =
zener diodes
Isolating
transformer
Galvanically isolated interfaces perform the same basic functions as zener barriers, namely:
 to limit the current into the hazardous area to a safe level at the given maximum voltage
 prevent mains breakthrough
The most obvious single difference between galvanic isolators and zener barriers is that no earth
connection is usually required. The galvanic isolation also means that the hazardous area circuit can be
earthed as a matter of convenience and intrinsically safe or simple apparatus which would not withstand
the normal 500 Vrms test can be used. Sometimes the factor governing the choice between zener barriers
and galvanic isolators is the difficulty of providing and maintaining a high integrity earth system. In such
cases the small additional unit cost of galvanically isolating devices is off-set by the cost of the earth
system required for zener barriers.
Although the ‘safety earth’ is not required for galvanic isolators, an equivalent level of safety is achieved
by the use of an isolating transformer (or similar device) which ensures that breakthrough of an excessive
voltage from the safe area electrical equipment is so unlikely that the possibility can be ignored.
©Sira April 2001
7.9 Comparing barriers and isolators
Zener barriers Galvanic isolators

 ‘Barrier earth’ essential  No earth required for I.S.
 Second earth in hazardous area  Use when earth in hazardous area is
not permitted required/unavoidable
 Earth fault in cable affects signal  Earth fault in cable does not affect
signal
 Preferred for Zone 0
Although zener barriers are somewhat cheaper, this may be off-set by the requirement to provide and
maintain the barrier earth. Galvanic isolators thus have the following advantages and are the interface of
choice for most applications:
 May be cheaper to install in a remote location as no earth required
 Allows use of equipment (e.g. pH probes) which cannot meet 500V isolation requirements
 May be used when there is an operational requirement to earth the equipment in the hazardous
area
 When earth-free, a single earth fault does not cause the system to ‘go down’, even if the earth
fault is on the supply line
 EN 60079-14 clause 12.3 recommends galvanic isolation for zone 0 systems.
7.10 Intrinsically safe hazardous area apparatus
Question: If an instrument is fed from a barrier or isolator, why

does it usually need to be certified?
Answer: because the instrument may:
 store energy in capacitors and inductors
 contain a voltage doubling IC
 get too hot under fault conditions
 have other sources of supply, e.g.
- battery back-up
- photocell
- additional inputs
It is sometimes assumed that supplying any uncertified instrument through a barrier makes the system
intrinsically safe. This is not generally true because the design of the barrier and the instrument meet
different criteria: the barrier limits the voltage and current into the hazardous area to a safe level whereas
the instrument is designed not to store up too much energy (in capacitors or inductors, for example) which
could then be released in an incendive spark. However, an exception to the rule that all equipment must
be certified can be made in the case of ‘simple apparatus’.
©Sira April 2001
7.11 Simple Apparatus
Simple apparatus must not generate or store more than

1.5V 100mA 25mW 20J
Examples
 terminals
 switches
 thermocouples
 resistance thermometers
 LEDs
 photocells
 Certification not required, but mark as ‘simple apparatus’
 I.S. requirements for 500V isolation and separation still apply
Simple apparatus may be used in an intrinsically safe system without requiring certification. Simple
apparatus must not generate or store significant levels of voltage, current, power or energy, as applicable.
The values above are taken from EN 60079-14 clause 3.21, which also requires that the values of
capacitors and inductors are considered when determining the overall safety of the system.
Such devices can be inserted into certified or uncertified systems without adversely affecting intrinsic
safety provided their temperature elevation is acceptable and, generally, they have passed a 500 V
isolation test (see BS5345:Pt 4 clause 6.3.3). However, as it would be confusing for a person carrying out
a hazardous area inspection to see uncertified equipment, such equipment should be clearly marked to
indicate that it is simple apparatus in an intrinsically safe circuit. Guidance on temperature classification
is given in EN 60079-14 clause 5.3: if the power available to the simple apparatus does not exceed 1.3 W,
switches and junction boxes are given a T6 temperature class and other equipment T4.
It should be remembered that simple apparatus is a concept that exists only within the context of an
intrinsically safe system. An uncertified thermocouple in a zone 0 or 1 is not permitted unless it is
supplied via a barrier or isolator, thus forming part of an intrinsically safe system.
7.12 Certified Systems
The certification body issues certificates for:

 the instrument and
 the system (instrument + associated apparatus)
In addition to the required apparatus certification marking, the system

information should also be displayed in a prominent place (e.g. on the
instrument)
SYST
Sira 00E2999
Certified systems are systems which are certified in their entirety by the certification agency and therefore
all that is necessary for the designer to do is to work within the terms of the particular system certificate.
The system certificate will not only show which barriers/isolators may be used with a piece of I.S.
apparatus, but will also give guidance on how much cable is allowed without invalidating intrinsic safety.
©Sira April 2001
7.13 Uncertified systems (system assessment performed by installer)
Um = 250Vac
Uo = 28V Ui = 30V
Io = 100mA Ii = 250mA
Po = 0.7W Pi = 1.3W
Co = 650nF Ci = 50nF
Lo = 11mH Li = 0
BARRIER/ISOLATOR INSTRUMENT
[EEx ia] IIB EEx ib IIC T4
 Ui, Ii & Pi must be at least as much as Uo, Io & Po
 Ci must be less than Co to allow for Ccable
 Li must be less than Lo to allow for Lcable
 System code reflects ‘weakest link’: EEx ib IIB T4
Where it is proposed to use two (or more) items of associated apparatus, the combined current or power
may well be excessive. Assume the combination of two such items is NOT acceptable unless it has been
proved to be intrinsically safe. It is a case of “guilty until proved innocent”.
Typically, a piece of associated apparatus (a barrier or an isolator, for example) will state its maximum
output voltage, current and power as well as the maximum capacitance and inductance which may be
connected. The instrument marking will usually state how much capacitance and inductance appears at its
terminals (if not, refer to the certificate), but account must also be taken of the cable capacitance and
inductance. The normally quoted parameters for the associated apparatus and the instrument are:
Associated apparatus Instrument

Um (max. fault voltage from power supply Not applicable
- usually 250 V ac)
Uo (max open circuit voltage) must be no more than… Ui (max. input voltage
Io (max. short circuit current) must be no more than… Ii (max. input current)
Po (max. output power must be no more than… Pi (max. input power
Co (max. external capacitance) must be larger than… Ci (effective capacitance)
Lo (max. external inductance) must be larger than… Li (effective inductance)
Cable capacitance and inductance must be taken into account. The values per metre of cable should be
obtained from the cable manufacturer, but the following may be taken as typical values:
Cable capacitance: 160 pF/m Cable inductance: 0.65 H/m
Beware – mineral insulated copper cable (‘pyro’) has a very high capacitance per metre.
Note: the symbols used above are those used in EN 60079-14 and in many cases differ from symbols used
on existing equipment. Alternatives include:
New symbol Existing symbols New symbol Existing symbols

Um Um
Uo Uz, Umax:out, Umax, Vmax:out Ui Umax:in, Umax, Vmax:in
Io Imax:out, Imax, Ik Ii Imax:in, Imax
Po Wmax:out, Wmax Pi Wmax:in, Wmax
Co Cext, Cout Ci Ceq, Ceff,
Lo Lext, Lout Li Leq, Leff
©Sira April 2001
7.14 Cable capacitance calculation
Assume the Co value of the associated apparatus is 650 nF and the Ci of the instrument is 50 nF.
 Ccable = Co - Ci = 650 - 50 = 600nF

 Typical cable is 160pF/m (0.16 nF/m)
 Maximum cable length = 600/0.16 = 3750 metres
NOTES:
 Some cable is 300pF/m or more
 IIC systems have much less capacitance available for cable at
higher voltages
A similar calculation may be done for cable inductance. Although cable contains capacitance and
inductance, their effects are reduced by the resistance inherent in the cable. In the case of inductance, the
L/R ratio is sometimes stated instead on the equipment. This requires the user to select cable with an L/R
ratio less than that specified. There is no equivalent C/R ratio for capacitance.
©Sira April 2001
CHAPTER 8
INCREASED SAFETY, Ex e
8.1 The principle of Ex e
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Ex e equipment is capable of being used in zone 1 or 2 with any flammable gas or vapour (subject to the
temperature class being appropriate), but Ex e apparatus is not sub-grouped like Ex d or Ex i. The
method of protection can only be used for equipment which does not spark or reach very high
temperatures in normal operation and so there are some items which cannot be certified Ex e - switches,
fuses, commutator motors, halogen bulbs, electronic components, for example – and it is common for
Ex e to be combined with other protection concepts. One very common combination is a stop-start
enclosure, which may have a certification code as follows:
EEx ed IIC T6
This will contain one or more small component-approved flameproof switches protected by an increased
safety housing.
The level of protection against dust and water is a minimum of IP54. Translated, IP54 means that Ex e
enclosures must be reasonably dust-proof and can keep out water from all directions. Thus, it should be
possible to install an Ex e enclosure in any orientation. Unofficially, IP54 is referred to as 'weatherproof'.
Clearly, if arcs and sparks are avoided by design, then the electrical circuits must be protected from water
and conductive dusts which could cause tracking and eventual breakdown on the insulation.
If a flammable gas/air mixture is ignited inside an Ex e enclosure, unlike flameproof there is no protection
left - the enclosure is not designed to withstand an explosion! The ingress protection of IP54 minimum
covers the exclusion of dust and water only, so the enclosure is not gas-tight. It is therefore vital that no
sources of ignition are present in such enclosures. Items that should definitely not be installed inside an
Ex e enclosure include:
 fuse terminals, even if certified ‘Ex N’ or ‘EEx n’
 test-disconnect terminals* (‘knife-edge switches’), even if certified ‘Ex N’ or ‘EEx n’
 uncertified terminals*, relays, fuses
 any uncertified electrical equipment
* unless part of an intrinsically safe system
©Sira April 2001
8.2 Certification
 EN 50019:1977 (BS 5501)

- European ‘first edition’
 EN 50019:2000
 European ‘third edition’
- with EN 50014, it covers most EHSRs of ATEX 94/9/EC Directive
 IEC 60079-7:1990
 FM 3619 (USA)
 UL2279:7 (USA)
 CSA-E79-7 (Canada)
The relevant codes of practice for Ex e equipment are

 BS 5345:Part 6 (1978)
 EN 60079-14 (installation), especially clause 8 - supersedes BS 5345 for new installations
 EN 60079-17 (inspection) - supersedes BS 5345 for new installations
8.3 Characteristics of Ex e enclosures
Case withstands
7 J impact
Material suitable
Gasket or O-ring to
for environment
give IP54 minimum
(frequently plastic)
Ex e apparatus is robust in construction and must pass an impact test on the enclosure, which must also
have protection against the ingress of dust or moisture. However, these are not onerous requirements and
Ex e enclosures are usually cheaper and easier to maintain compared to flameproof enclosures.
With the exception of discrete plastic glands, there is no need for certification in Ex e applications (see
chapter 12). However, certified Ex e glands do exist and these can be used, as can all other types of metal
gland provided an ingress protection of IP54 can be achieved at installation. When installing MICC cable,
the standard glands are acceptable, however it is advisable to use the certified increased safety seal to
terminate the cable so as to be sure of complying with the insulation and segregation requirements for
Ex e.
©Sira April 2001
8.4 Ingress protection
Numeral Protection of equipment Protection of persons against

against ingress of solid access to hazardous parts
foreign objects
First characteristic numeral
0 No protection no protection
1 50mm diameter back of hand
2 12.5mm diameter finger
3 2.5mm diameter tool
4 1.0mm diameter wire
5 dust-protected wire
6 dust-tight wire
Second characteristic numeral
0 No protection
1 vertically dripping
2 dripping (15 tilted)
3 spraying
4 splashing
5 jetting
6 powerful jetting
7 temporary immersion
8 continuous immersion
8.5 Terminals
Locking device Pressure plate

to prevent loosening between screw
and conductor
Terminals in an Ex e enclosure must be certified. If the terminals can be removed (as with rail-mounted
Klippon/Weidmuller terminals, for example), then they should be individually certified. The usual coding
is ‘EEx e II’. Terminals which are not removable will be certified with the equipment and need not be
individually marked with a certification code. Locking devices are incorporated in terminals so that they
will not work loose. Clearance between terminals and creepage distances on insulating material are
arranged to meet minimum requirements.
©Sira April 2001
8.6 Limitations of the Ex e concept
Limitations on internal components:

- no switches (unless Ex d)
- no test-disconnect terminals
- no fuses (unless otherwise certified) of fuse terminals
- Ex e does not cover electronic circuitry:
capacitors must be otherwise protected, e.g. Ex d, Ex
q
8.7 Inspection of Ex e enclosures
BS 5345 and EN 60079-17 checklists:

 Gasket/O-ring in good condition?
 Clean and dry?
 All terminals tight?
 Any loose strands?
 Insulation cut too far back?
 Conductors badly crimped?
 Two conductors in terminals designed for one?
 All terminals certified Ex e?
 Partitions between terminals of different sizes?
Ex e junction boxes are frequently used to house terminals for intrinsically safe circuits. Although
intrinsically safe and non-intrinsically safe circuits are allowed in the same junction box if segregation
requirements are met, it is best avoided if possible. In larger junction boxes and panels, the intrinsically
safe and non-intrinsically safe conductors must be usually separated by 50 mm through air unless a non-
conducting partition is used.
BS 5345:Part 1 and EN 60079-14 require that equipment should be suitable for the environmental
conditions. It is important to ensure that any vapour which might have an adverse effect on equipment is
checked with the manufacturer to ensure that their equipment is proof against it.
8.8 Luminaires
Two types:
 Single pin TLX fluorescent tube, choke with large heat-sink, Ex
d switch and Ex d or Ex q capacitor, typically EEx ed or EEx edq
 Twin-pin hot cathode tube, typically Ex eds
These are likely to be lighter than their flameproof equivalents and also easier to maintain. Ex e
luminaires usually incorporate components protected by other methods, such as:
1 EEx d lamp-holder (in case a spark occurs)

2 EEx d cut-out switch (to disconnect the battery in an emergency light)
3 Capacitor protected by EEx d or EEx q in case of overheating
4 Battery back-up with batteries surrounded by sand in an EEx q enclosure
5 EEx ib/d electronics to switch from mains to battery back-up
©Sira April 2001
8.9 Ex e motors
Ex e motors are more stringently designed than most others in that:-

 They can be stalled at working temperatures for at least 5 seconds without any part of them, including
the rotor, exceeding the temperature classification;
 A minimum size of wiring is specified unless fully encapsulated;
 The rotor/stator air gap is deliberately enlarged to make it even less likely that the rotor will hit the
stator when the bearings are worn;
 Frequently the Ex e frame is larger than for other motors of the same rating because of lower
efficiency.
It is important with all motors for Ex e that the overcurrent or overload settings and trip times on the
starters are as required by the motor certification.
8.10 tE time of motors
Temperature
limiting temperature
Current
tE time
time
motor stalled
The electrical protection gear must remove the supply from the motor within the 't E time' of the machine
and considerable care is needed in selection of the protection device, because of the delay in the control
gear operating. The tE time is the time taken for an a.c. winding to heat up from its maximum service
temperature to:
1 either the limiting temperature for the T-class
2 or the maximum allowable temperature to prevent degradation of insulation and other
constructional materials
The tE time must beat least 5 seconds and the ratio of start current to running current must not be more
than 10. The tE time is part of the certification marking for an Ex e motor; there may be different tE times
for different temperature classes
.
©Sira April 2001
CHAPTER 9
PRESSURISATION
9.1 Introduction
Ignition-capable apparatus is housed in an enclosure, which should be fairly air-tight,

and a pressurising gas, either air or some inert gas, is piped into the enclosure so that the
internal pressure is maintained above atmospheric pressure. The objective of this internal
over-pressure is to prevent an external flammable atmosphere entering the enclosure.
The technique of pressurising and purging enclosures of electrical apparatus to prevent the ingress of a
flammable atmosphere has been with us for many years. One of the chief virtues of this technique is the
ease with which the basic philosophy can be grasped and the fact that it can be retrospectively fitted to
protect uncertified equipment which is already installed.
Unlike the other methods of protection this technique is virtually unlimited particularly in the physical
size or power rating of the apparatus being protected. Applications vary in size from a small enclosure for
a single instrument up to an entire off-shore accommodation module - the former can be certified but the
latter cannot. As the flammable gas is kept out, certified apparatus is applicable to the gases of all gas
groups, provided the T-class is appropriate.
The latest European standard is EN 50016:1995 which extends and supersedes EN 50016:1977
(BS 5501:Part 3:1977).
Because of the apparent simplicity of the technique it has, historically been applied by individual
engineers on an ad hoc basis and it is common for equipment based on the Ex p standard to be used as the
basis for protection in zone 2 areas without certification being sought.
9.2 Typical arrangement
Pressure Switch
Outlet Control
Ignition-
capable
Protective gas equipment Flow Meter
Fan
Controller
Non-hazardous Hazardous area
area
©Sira April 2001
9.3 Types of pressurised equipment
Leakage compensation (air or inert gas)

flammable gas analysers
VDUs
motors
Continuous circulation (air also acts as coolant)
motors
Continuous dilution (usually air)
control rooms
analyser houses
Static pressurisation (inert gas - portable items only)
torches
Where applicable, the controller ensures that the electrical equipment cannot be energised until the
enclosure has been purged with the prescribed number of air changes.
The pressurisation method can be applied in various forms:
1 Leakage compensation - the enclosure is purged, then the outlet control closed and the protective gas is
only supplied when the pressure approaches the allowed minimum. This method is not normally used
where there may be a release of a flammable gas in he enclosure(such as in a gas analyser), but can be
if an inert gas (usually nitrogen) is be used;
2 Continuous circulation - the protective gas, usually air, is continuously circulated through the
pressurised enclosure. This commonly applies to motors where the protective gas is also used for
cooling;
3 Continuous dilution - as the name suggests, the protective gas (always air) is supplied continuously to
dilute any release of flammable material within the enclosure. This method can also be used for
enclosures such as pressurised control rooms where people are going in and out (though certification is
not possible);
4 Static pressurisation - the enclosure is sealed as completely as possible and pressurised in the non-
hazardous area. It can then be moved into the hazardous area where it can be used without further
pressurisation unless the pressure drops below the allowed minimum.
Typical applications of the four types of pressurisation are as follows:
9.4 Required overpressure
The minimum over-pressure is quite small - 50 pascals (0.5 mbar). If the pressure falls below this level,
the controller can usually be programmed to react depending on the risk:
Zone Equipment is ignition-capable in Equipment is not ignition-capable in

normal operation normal operation
1 Alarm & trip Alarm

2 Alarm Alarm
Usually, the pressurising system is arranged so that the enclosure can be purged to remove any
accumulation of flammable gases before the apparatus within is switched on. This may not be necessary
in a zone 2 provided a flammable gas check is performed.
©Sira April 2001
9.5 Constructional requirements
All pressurised apparatus must meet the following minimum requirements of the standard:
1 Flow meter to monitor that initial purge and subsequent flow is sufficient
2 It is not possible to over-ride the initial purge
3 Overpressure monitored and maintained
4 Protection against excessive pressure
5 Alarm and, possibly, isolation of electrical equipment, if overpressure falls below 50 Pa
6 Internal equipment must not act as a gas trap - holes may need to be drilled to avoid ‘dead spots’.
Consequently, enclosures within the main enclosure may not be allowed.
7 There should be no energy-storage devices (capacitors, batteries) which store energy and spark
incendively when the equipment is isolated. Such devices may be acceptable if made intrinsically
safe with current-limiting resistors, for example.
9.6 Maintenance
Aspects to look for when maintaining Ex p equipment are:

 Is the air intake located in the non-hazardous area?
 Is the fan located so as not to produce an underpressure in the ducting?
 Do the underpressure and overpressure alarms operate correctly?
 Verify the initial purge
 Does the enclosure leak?
For maintenance purposes it is necessary to work on the apparatus within the enclosure while the purge is
off and the enclosure is open. Usually this is done under a gas clearance or hot work permit for safety but
there are other safety implications which have to be taken into account.
Once the enclosure has been opened the pressure switch will, via the control unit, cause the power to be
isolated from the enclosure. Naturally power must be on so some means are required to by-pass this
function of the control system. One way of achieving this is to wire a key-operated switch in parallel with
the pressure switch. This prevents the loss of pressure from causing the enclosure to be isolated. However
this has two disadvantages:
1 No re-purge takes place automatically when the enclosure is closed;
2 No alarm is raised in the control room.
An alternative is to fit a key-operated switch in parallel with the contacts which energise the contactor.
This technique does not suffer from the previous two disadvantages but is not without problems because
the key-operated switch is usually remote from the enclosure and is not, therefore, under the close control
of the person working on the enclosure. The key cannot be removed until the re-purge is complete.
9.7 Advantages of pressurisation
 Allows uncertified equipment to be incorporated into a certified item of Ex p apparatus and used in a
hazardous area
 Few limitations on internal electrical equipment
 No limit to enclosure size
 Caters for all flammable gases: EEx p equipment is not sub-grouped
 Frequently T6 as only the external enclosure temperature is assessed - the internal components are not
exposed to the flammable gas
©Sira April 2001
9.8 Disadvantages of pressurisation
 The enclosure and ducting may leak

 Energy costs associated with maintaining the pressure of the protective gas
 Modifications may be required to avoid ‘dead spots’
 Rather complex/expensive for small items
©Sira April 2001
CHAPTER 10
Type n/N, EEx n/Ex N
10.1 Principles of type n/N protection
Apparatus that is incapable of igniting

an external flammable gas atmosphere
under worst-case
normal operating conditions
Suitable for zone 2 only
Type of protection n (or N) is a Category 3 method of protection, for Zone 2 only. It is referred to an
‘non-incendive’ in the USA. The probability of a flammable atmosphere arising in Zone 2 is low and,
consequently, the level of protection provided by Type n is somewhat less than for Category 1 and 2
equipment; it is required to be safe in normal operation. It is basically non-sparking equipment which
does not become hot but, where sparks or excessive surface temperatures occur, simplified versions of the
other methods of protection are used.
10.2 Certification
Ex N complies with
BS 4683: Part 3 (1971) or
BS 6941:1988
EEx n complies with

IEC79-15:1987 or
EN 50021:1999
There are also other national standards
Most of the equipment certified for zone 2 in Europe is certified to a national standards, since the
European standard is relatively recent (1999). Before the publication of this standard, it was difficult for
manufacturers to obtain certification valid throughout Europe, as IEC79-15 has not been widely accepted
in some countries. It is intended that IEC79-15 and EN 50021 will eventually be technically identical.
EN 50021 is the best standard to use as a basis for ATEX certification for Category 3 electrical equipment.
Equipment certified to, for example, BS 6941 must be re-assessed against EN 50021 before an assessment
against the EHSRs of the ATEX 94/9/EC Directive is undertaken. EN 50021 is considerable more
onerous than BS 6941.

©Sira April 2001
10.3 Protection methods used by Ex n/N
Non sparking
simplified Ex e (e.g. terminals, junction boxes, luminaires,
motors)
Exclusion of flammable gas

simplified Ex p and Ex m
Energy limitation
simplified Ex i (e.g. in-cab computers, PLCs)
Enclosed break
Type n uses the principles of all of the main methods of protection but usually only normal operation is
considered, not fault conditions. This means that it is often cheaper than the equivalent equipment which
can be used in zone 1. In general, Type n has most in common with increased safety and it may appear
that simplified increased safety (referred to as ‘Ex n non-sparking’) is a complete definition of Type n.
However, Type n modifies most of the zone 1 methods of protection and can be discussed under four
headings:
1 Non-sparking: industrial apparatus which does not spark or become excessively hot in normal
operation and which is constructed to a minimum standard of reliability. This is similar in
concept to Ex e but has a lower level of integrity.
Sparking apparatus or apparatus that gets hot where the part which sparks or becomes hot is
protected in some way such as:
2 Keeping the flammable gas out

 by encapsulation (similar to Ex m)
 by hermetic sealing
 by sealing
 by use of restricted breathing enclosure (similar to static pressurisation)
3 Energy limitation
 limiting the spark energy (similar to Ex i)
4 Enclosed break
 similar to small volume Ex d devices like lamp-holders, switches
The objective of the Type n standard is to provide a single concept which will allow any type of apparatus
with protection similar to most of the types of protection used in Zones 1 and 0, but on a much simpler
scale.
Equipment certified to British standards BS 4683 and BS 6941 designate the equipment ‘Ex N’ and there
is usually no distinction made in the certification marking between the various different methods of
protection within the overall concept. The exception is for restricted breathing, where the standards
required this to be marked on the label, to alert users to the routine pressure test required.
Equipment certified to IEC79-15 or EN 50021:1999 has a suffix to indicate the method of protection used
– see sections 10.5 to 10.10.

©Sira April 2001
10.4 Type n enclosures
Gland must also maintain IP54;

washer required Case withstands
3.5 J impact
Material suitable
for environment Gasket or O-ring to
(frequently plastic) give IP54 minimum
Note that the impact test is less severe than for Ex e (7 J required).
The requirements for terminals are similar to those for increased safety, though rather less onerous.
Terminals are required to be non-loosening and with a pressure plate between the screw and the
conductor; there is no requirement for terminals in Type n/N equipment to be certified, though such
certified terminals are available. As a relaxation to Ex e requirements, fused terminals and test-disconnect
terminals are permitted in Type n enclosures.
10.5 Non-sparking equipment (designated EEx nA in EN 50021)
 Simplified Ex e
 Enclosure usually IP54 minimum
 Condition of gaskets and O-rings is important
 Common examples are
 junction boxes
 luminaires
 motors
This is similar to Ex e equipment and as such particular attention should be given to the weatherproofing
of the enclosure, noting the condition of the gasket, and ensuring that all terminations are tight and sound.
This applies to all Type n equipment, even if other methods of protection predominate.

©Sira April 2001
10.6 Energy limitation (designated EEx nL in EN 50021)
Simplified intrinsic safety

Local protection of switches, etc
a simplified barrier may be used
power
supply
haz. area non-haz. area
This is simplified intrinsic safety, without the consideration of fault conditions, and is an important
method of protection for zone 2instrumentation.
Apparatus is protected in one of two ways, or a combination:
1 Each sparking component (switches, relays, potentiometers, connectors, jumpers) is protected on

an individual basis by use of resistors, sealing, hard-wiring or mechanical retention as appropriate.
2 The voltage and current to the apparatus is limited either by zener diode/resistor circuitry at the
input or in the non-hazardous area. It is likely that simplified ‘barriers’ will be available in future
to achieve this.
10.7 Restricted breathing (designated EEx nR in EN 50021)
 Uses include computers, VDUs, lamps, etc.

 Not suitable for frequent start/stop cycles
 Not suitable if dissipating high power
 The apparatus is mounted in an enclosure which is as gas-tight as possible
BS6941 limits this application to equipment which does not spark, restricting the application to apparatus
such as luminaires. However, no such limitation applies under IEC 79-15 and EN 50021, and devices
©Sira April 2001
such as computers, VDUs and other apparatus may be certified EEx nR under this standard, making it a
very versatile method for getting electrical equipment into a zone 2. From a maintenance point of view,
the crucial aspect is the condition of gaskets and seals which are relied upon to make the enclosure almost
gas-tight: the certificate will probably define the pressure test to be carried out periodically.
EEx nR is not a suitable concept for protecting electrical equipment that

 dissipates excessive power – a mean temperature rise of 10 K within the enclosure is permitted
 operates on a duty cycle with frequent on-off operation
10.8 Enclosed break equipment (designated EEx nC in EN 50021)
Simplified flameproof
Max. enclosure volume 20 cm3
Relatively unimportant - switches, lampholders, etc.
lamp
Equipment designated EEx nC applies to any sparking equipment not protected by energy limitation or
restricted breathing. See also section 10.7.
EEx nC enclosed break is similar to flameproof equipment but the maximum enclosure volume is 20 cm3,
which is too small for there to be any glanding considerations. This method is relatively rare and
unimportant, being reserved for applications such as switches and lamp-holders.
10.9 Encapsulated, sealed & hermetically sealed equipment (EEx nC in EN 500021)
Such components are

required to pass
a simple sealing test
involving immersion in hot water
[The technique is more often used for small components

in a larger item]
This is usually applicable to components such as relays; they should be checked for signs of cracking,
solvent attack and other damage. Compliance with the standard is shown by a simple test.
10.10 Simplified pressurisation (designated EEx nP in EN 50021)
This technique is under development and will be included in EN 50021 at a later date.

©Sira April 2001
10.11 Cables and glands
Cables
- as for zone 1
- much rugged industrial cabling is adequate
Glands
- certification not required
- normally required to be IP54 minimum
- special consideration for glands into restricted breathing
enclosures
Under the European Code of Practice, EN 60079-14:1997, the cables allowed in zone 2 are to be of the
same standard as those in zone 1 (see Chapter 12). Termination of cables should be through normal
industrial compression glands except for techniques such as restricted breathing where sealing of glands is
necessary; otherwise the normal Ex n requirement of IP54 should be maintained.
There is no requirement for glands to be certified, but, clearly, the use of Ex d or Ex e glands is allowed.

©Sira April 2001
CHAPTER 11
Ex q, Ex o, Ex m & Ex s
11.1 Quartz (sand) filling, Ex q
In Ex q apparatus:
the parts which may cause ignition are immersed

in a powder such as granulated quartz;
the flame cannot burn outwards through the
quartz powder, so is quenched.
The mark Ex q is applied to equipment certified to comply with:

1 EN 50017:1994 (‘second edition’)
2 BS 5501 Part 4 :1977/EN 50017:1977 (‘first edition’)
3 IEC 79-5 Part 5 (1967)
BS 5345 does not recognise this as a method of protection for zone 1, so Ex q equipment has only be
installed in zone 2 under BS 5345. However, it has been accepted in zone 1 in some of the other
European countries and this has been used as justification for a zone 1 installation in the UK, but the onus
has been on the user. The second edition of the standard imposes more stringent constructional
requirements for Ex q apparatus and consequently EN 60079-14:1997 allows EEx q in zone 1.
Typical applications are the protection of components such as battery packs and capacitors.
11.2 Oil immersion, Ex o
Ex o apparatus complies with:

1 EN 50015:1994 (‘second edition’)
2 BS 5501 Part 2:1997/EN 50015:1977 (‘first edition’)
3 IEC 79-5 Part 6
In Ex o apparatus:
ignition is prevented by
immersing the ignition risk in such a depth of oil
to prevent any ignition above the surface.
This method of protection is rather limited in its application. The second edition standard does not allow
sparking apparatus such as switchgear to be protected by Ex o, which is more limiting than the first
edition standard. Consequently, the European Code of Practice allows Ex o equipment in zones 1 and 2,
whereas BS 5345 restricted the method to zone 2 only.

©Sira April 2001
11.3 Encapsulation, Ex m
Ex m is:
a type of protection in which

the parts which could ignite an explosive atmosphere
by either sparking or heating are enclosed in a compound
in such a way that this explosive atmosphere cannot be ignited.
e.g. ultrasonic transducers

temperature sensors
magnetic limit switches
relays
Ex m is relatively new standard (EN 50.028:1987) and no ‘Second Edition’ is currently envisaged.
BS5345, the British Code of Practice, does not consider this means of protection. The treatment in
EN 60079-14 is to define the method and allow it into zones 1 and 2, but no specific installation
requirements are given. A high integrity version of this method of protection is detailed in
EN 50284:1999; it is designated ‘EEx ma’ and is permitted in zone 0.
Ex m has various applications, typically fairly small enclosure. The encapsulant also acts as a cooling
medium for the components.
The intrinsic safety standards also defines encapsulation, so encapsulated components within intrinsically
safe apparatus are not necessarily EEx m and so the letter ‘m’ does not appear in the certification code.

©Sira April 2001
11.4. Special protection, Ex s
 For equipment not covered by the existing standards, or

 For equipment that does not meet the requirements of an existing standard
but which can, nevertheless, be shown to be safe
No European standards exists
Most Ex s equipment is Category 2, occasionally 1
Legal requirements for safe working in the UK have been based on legislation which lays down the need
for working and indicating those responsible for ensuring that safety. Detailed procedures have been left
to codes of good practice produced by recognised bodies. This form of control has encouraged a high
degree of safety coupled with opportunity for innovation.
Standards have now been produced to cover a very wide range of apparatus for use in hazardous areas,
and the number of occasions which suitable items are not available is much smaller than previously.
Nevertheless, such occasion to arise. It was once possible to obtain 'approval' for equipment which, while
not conforming to any regular standard, could be shown to be unlikely to cause ignition. Such equipment
may nowadays be certified Ex s.
Ex s is the term applied to apparatus which has been found to comply with BASEEFA Certification
Standard SFA3009. This therefore results in a national certificate; there is no European standard. Ex s
equipment is often certified as safe for a specified zone (including any less hazardous) for which the
examination proves the item to be suitable. Generally, it is suitable for use in zones 1 and 2, but a piece of
equipment can be specifically certified for zone 0 – the marking will make this clear.
The need for Ex s certification vanishes once a standard for the specific technique becomes established
and recognised by industry and the certifying authority. Sinters were not formerly covered under any of
the EN50-series standards and equipment like gas sensing heads were certified Ex ds. However, EN
50018:1994 includes sinters for the first time, so sensing heads can now be certified EEx d. The
important point about Ex s is that it covers apparatus which can be shown by test to be safe but which
does not comply with any of the other concept standards.
Techniques used in this form of protection are not limited. There is opportunity for innovation as the
following examples illustrate:
 total encapsulation in resin or hermetic sealing to prevent the access of vapour (now EEx m or EEx n),
 sinters in the chamber of gas detection apparatus where the gas sample is burnt (now EEx d),
 heavy mechanical protection of ignition sources such as a small bulb in a torch (now EEx e),
 a compound filled box containing an electromagnetic coil (now EEx m).
 non-sparking lampholder for a twin-pin fluorescent tube in an Ex es luminaire; the lampholder must
not spark even under extreme vibration.

©Sira April 2001

Flameproof Equipment CH 06-11 April 01

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CHAPTER 6

6.1 The flameproof principle

Electrical equipment which may ignite a flammable

 The enclosure provides the protection rather than the

BS 4683 equipment is similar to that constructed to BS 5501:Part 5/EN 50 018:1977.

6.4 How Ex d equipment works

Perfect seal Gaps permitted

NOTE: the enclosure does not require a gap to relieve

t6.6 The mechanism of quenching

Max. gap (mm)

IIC gases are best at burning through gaps

6.8 Obstruction of flamepaths

 EN 60079-14 and BS 5345 require the following

 IIA gases: mainly cooling by expansion

6.9 Obstruction of flamepaths: tape

‘Denso’ tape reduces effectiveness of flamepaths

Gas group Allowed MESG MESG

6.10 Obstruction of flamepaths: paint

 EN 60079-14 states that paint should be

 Good practice dictates that flamepath

6.11 Obstruction of flamepaths: gaskets and O-rings

 The user should not add gaskets or O-

 An IP washer is allowed when installing a

 Grease is permitted but must be

6.13 Greasing bolts

casing may crack

6.14 Electrical protection

6.15 Pressure piling

An explosion in one …. pre-pressurises gas

6.16 Stopper boxes

Must have stopper boxes

A typical schedule of limitations:

7.1 The principles of intrinsic safety

Principle - ‘safe spark’ concept:

Group IIC (hydrogen/air) limited to…. 40 µJ

The following standards deal with intrinsically safe equipment:

Only use the battery type specified on the label

7.4 Fixed equipment – a typical intrinsically safe system

Two main types: Current (mA)

- to limit the current into the Permitted current is 2/3 of

at the given voltage

There are basically two types of interfaces, known as ‘associated apparatus’:

Marking: associated apparatus is indicated by square brackets, for example:

I.S. earth required

There are two basic safety requirements of a shunt-diode safety barrier.

Hazardous area Instrument transformer

7.8 Galvanic isolators

resistor fuse ac/dc converter

Zener barriers Galvanic isolators

7.10 Intrinsically safe hazardous area apparatus

Question: If an instrument is fed from a barrier or isolator, why

Simple apparatus must not generate or store more than

7.12 Certified Systems

The certification body issues certificates for:

In addition to the required apparatus certification marking, the system

Associated apparatus Instrument

New symbol Existing symbols New symbol Existing symbols

 Ccable = Co - Ci = 650 - 50 = 600nF

8.1 The principle of Ex e

Ignitiono faflamm ablega

* unless part of an intrinsically safe system

 EN 50019:1977 (BS 5501)

The relevant codes of practice for Ex e equipment are