Professional Documents
Culture Documents
Prologue
Can you identify the differences in how these areas should be classified and the differences in wiring practices? If not,
then this digest is a must read for you.
The purpose of this document is to explain the concepts of hazardous areas, the differences between Zones and
Divisions, the different explosion protection techniques and how electrical equipment is installed in hazardous locations
around the world. For more detailed information on the equipment available and the installation methods used, ask
your Cooper Crouse-Hinds® representative for a copy of the Electrical Code Digest or contact the author at
Paul.Babiarz@crouse-hinds.com
Area 1 Area 2
1. Which location should be classified as Zone 1 and which should be classified Zone 2?
2. What clues lead you to these conclusions?
3. What forms of explosion protection can you identify in the Zone 1 photo?
4. Describe the wiring practices used in these photos?
5. Are seals required?
Answers
1. Area 1 is Zone 1; Area 2 is Zone 2
2. Area 1 is adjacent to a process area. Area 2 is outside of a laboratory.
3. In Area 1 the phone handset and meters at the top of the panel are intrinsically safe - Ex-ia; the GHG 273 light
switch (bottom left) is flameproof and increased safety - Ex-de.
4. The wiring practices use flexible cables through an open conduit system that protects vertical runs of cable.
5. Explosionproof seals are not required because the switches and other are factory sealed and conduit is not used.
2 Cooper Crouse-Hinds Ex Digest
The Electrical Code Evolves
CHAPTER 1 The first electrical equipment used in the mines were motors to
THE ELECTRICAL CODE EVOLVES drive the elevators, ventilators and mining equipment. After the
sparking motors resulted in some mine mishaps, they were
The first electrical equipment used in the mines totally enclosed, which contained the explosions. This marked
the beginning of the metallic explosionproof enclosures with
were motors to drive the elevators,
tight-fitting joints later called flame paths.
ventilators and mining equipment.
In 1931 Class I for gases and vapors, Class II for dusts, and
Class III for fibers were defined. The Class I areas were further
subdivided in 1935 into the Groups A, B, C, & D (refer to section
2.4) based on the gases’ main characteristics of:
• explosive pressure
• flame transmission
• ignition temperature
CHAPTER 2
BASICS OF EXPLOSION PROTECTION
The determination of the amount of time that an
explosive mixture will be present in an
area is the basis of “area classification.”
For an explosion to take place, all three sides of the triangle, concentrations of flammable material. In other words, the
satisfying the following conditions, must be present: design must be suitable for the classification of the area in
which it is installed.
• There must be a supply of oxygen present. In most situations
this is applicable as a result of the oxygen content in the air Overall the design of equipment for the different “Zones” or
(21%). “Divisions” is based on ensuring the probability of the
• There must be sufficient fuel present in the air to form an simultaneous occurrence of a flammable gas (or vapor, mist or
ignitable mixture. The fuel may be in the form of a gas, dust) concentration and an ignition source from equipment is so
vapor, mist or dust. low that in practice it does not happen. It has been suggested
• There must be a source of ignition with sufficient energy to in a number of industry papers that the probability of an ignition
ignite the fuel-air mixture. For electrical equipment this may occurring once every hundred years is so low that in practice it
be from an arcing or sparking device or from a hot surface. will not happen. Probabilities at this level (approximately 1 in
There may be sources of ignition other than electrical 1,000,000) are similar to those done for the catastrophic failure
equipment, such as hot exhaust surfaces from internal of piping or vessels.
combustion engines. These devices do not fall within the scope
of the North American electrical codes and are normally 2.3 IGNITION SOURCES—GASES & VAPORS
covered by other codes and standards such as Occupational Ignition sources can occur by various mechanical means, but
Health and Safety. for the purpose of this publication we consider only electrical
sources of potential ignition.
The basic approach to design in a Hazardous Location is to
ensure that all three sides of the triangle do not exist The most important characteristics of flammable substances in
simultaneously. If any one side of the triangle is not present, an regard to ignition are:
explosion cannot occur. Protection against explosions will • Upper Flammable Limit
therefore require control or elimination of one or more sides of • Lower Flammable Limit
the triangle. • Flash Point of the flammable material
• Auto-Ignition Temperature
2.2.1 THE OXYGEN SIDE • Vapor Density
In most situations there is sufficient oxygen present in the air
(21%) to meet the conditions for an explosion. In some 2.3.1 UPPER & LOWER FLAMMABLE LIMITS
situations however, oxygen may be excluded by blanketing an There are a number of characteristics of gases and vapors that
enclosed area with another gas to ensure there will not be are important for the classification of a Hazardous Location and
sufficient oxygen present. The blanket gas is normally an inert the application of equipment within the Hazardous Location.
gas, such as nitrogen, or in some cases it may even be a
flammable gas such as methane. • LOWER EXPLOSIVE LIMIT (LEL)—is the lowest percentage
by volume of gas (or vapor) in a gas-air mixture that will form
2.2.2 THE FUEL SIDE an ignitable concentration. Below that concentration there is
If avoiding the use of flammable substances is not possible, the insufficient gas or vapor in the mixture and the gas-air mixture
fuel side of the triangle is removed by enclosing the gas or dust is too lean to be ignited.
in piping, or vessels in the case of gas, vapors or flammable
liquids, or in enclosed ducts in the case of dust. Of course there Flammable Limits
is always the possibility that flammable materials could be Class I Percent by Volume
Group Substance Lower Upper
released in sufficient quantity to form an explosive mixture as a
result of a malfunction of equipment. In some situations an C IIB Acetaldehyde 4.0 60
explosive mixture may be present frequently or continuously as D IIA Acetic Acid 4.0 19.9 @ 200°F
a result of normal operations such as the interior of vented fuel
D IIA Acetic Anhydride 2.7 10.3
storage tanks or the interior of paint spray booths.
D IIA Acetone 2.5 13
The determination of the amount of time that an explosive D IIA Acetone Cyanohydrin 2.2 12.0
mixture will be present in an area is the basis of “area
D IIA Acetonitrile 3.0 16.0
classification,” which is discussed in more detail in Chapter 3.
A IIC Acetylene 2.5 100
If the percentage of gas is below the lower limit, the mixture is Flammable limits are normally given at 25°C; an increase in
too lean (insufficient fuel) to ignite. The mixture is too rich temperature widens the flammable limits.
(insufficient oxygen) if the percentage is above the upper limit.
Some gases, such as methane, are ignitable over a relatively As a general rule, 12°C below flash point results in a flammable
narrow range of 5% to 15%. Methane is frequently used in the vapor concentration of 50% of the lower flammable limit. See
form of natural gas to provide a low-pressure gas blanket over Appendix I, “Gases & Vapors – Hazardous Substances Used in
liquid in a tank to ensure an ignitable mixture is not formed. The Business & Industry.”
presence of the natural gas blanket ensures the mixture in the
tank will always be above the UEL. Class I Flash Point
Group Substance °F °C
Other gases are ignitable over a relatively large range, such as C IIB Acetaldehyde -38 -39
acetylene (2.5 to 100%) and hydrogen, which is ignitable from D IIA Acetic Acid 103 39
4% to 75%. As hydrogen is a very light gas, it is often used in D IIA Acetic Anhydride 120 49
large turbine generators to reduce the friction loss of the rotor. D IIA Acetone -4 -20
Because of the extremely large explosive range of hydrogen,
D IIA Acetone Cyanohydrin 165 74
great care must be taken to ensure concentrations within the
D IIA Acetonitrile 42 6
generator do not enter the explosive range as the result of the
introduction of air. Refer to Appendix I NFPA 325 M-1991, Fire A IIC Acetylene gas gas
Hazard Properties of Flammable Liquids, Gases & Volatile Complete table is contained in Appendix I.
Solids, for the complete listing of gases and vapors.
2.3.3 AUTO-IGNITION TEMPERATURE
The ignition temperature of a gas, sometimes referred to as
“auto-ignition” temperature, is the lowest surface temperature
which will ignite the flammable atmosphere (independent of any
externally heated element). This becomes important when
determining the temperature rating, or T-rating, of an enclosure
or component. Published values of ignition temperature are
determined by injecting a gas sample into a heated flask to
determine the minimum temperature at which ignition takes
place.
Equipment tested only with group B gas would be marked “B” Increased Safety Ex-e terminal boxes normally have T6
only. In practice however, the North American system is Temperature Classification, i.e. 85°C maximum surface
unofficially treated as if a hierarchy similar to IEC existed. temperature if routine tested, or 80ºC if only type tested, at an
ambient of 40°C. Apparatus with a T6 Classification has a very
high degree of safety and can be used for all temperature
2.5 TEMPERATURE CLASSIFICATION classes. (The only listed gas in the temperature class T6 (85°C)
The selection of electrical equipment for use in hazardous
is Carbon Disulfide.)
areas must ensure that the maximum surface temperature of
any part of the apparatus exposed to the potentially explosive
It is important to evaluate the maximum operating temperature
atmosphere, does not exceed the auto ignition temperature
of cables connected to electrical equipment, particularly if the
(i.e., the temperature at which the substance when heated will
cable is PVC insulated. They normally have a maximum
ignite spontaneously).
operating temperature of 70°C. This is also in conformance
with the IEC standard IEC 60079-0. To make full use of the
Temperature classifications according to the North American
maximum operating temperature of T6 classified equipment,
and IEC 79-0 standards are detailed in Table 2.5.
cables with a 95°C rated insulation should be used.
Table 2.5
T-numbers for North America and IEC The minimum concentrations of dust that will explode
Maximum
are normally two or three orders of magnitude above
Temperature Surface Temperature acceptable concentrations for workers.
Classification North America IEC
T1 450°C 450°C
T2 300°C 300°C 2.6 IGNITION SOURCES—DUSTS
T2A 280°C - Some air suspended dusts will explode if ignited from a source
T2B 260°C - with sufficient energy. Materials that can create dust explosions
T2C 230°C - include:
T3 200°C 200°C
• Natural organic materials (grain, linen, sugar)
T3A 180°C -
• Synthetic organic materials (plastics, organic pigments,
T3B 165°C -
pesticides)
T3C 160°C - • Coal and peat
T4 135°C 135°C • Metals (aluminum, magnesium, iron, zinc)
T4A 20°C -
T5 100°C 100°C
2.6.1 MINIMUM EXPLOSIVE CONCENTRATION
T6 85°C 85°C For air suspended dust to explode it must be present in
quantities at or above the Minimum Explosive Concentration
The reference ambient temperature of 40°C will be assumed (MEC). The MEC of dust is defined as:
unless otherwise stated on the apparatus labeling. Normal test
requirements also assume that the tested equipment is suitable • The minimum concentration of dust in air that will explode
for lower ambient temperatures of minus 20°C. when ignited, expressed in grams per cubic meter (g/m3) or
in ounces per cubic foot.
The T-Classification allocated to Certified Electrical Apparatus
is based on normal temperature at the most difficult operating Typically, the minimum concentrations of dust that will explode
conditions. For example, the most onerous condition for an are normally two or three orders of magnitude above
increased safety, Ex-e, terminal box would be an enclosure acceptable concentrations for workers and are normally present
fitted with the maximum permitted number of terminals with only inside process equipment such as coal pulverizers,
every terminal carrying its maximum rated current and enclosed conveyor transfer points, silos, grain elevators, etc.
maximum cable lengths connected to each terminal. For example a glowing 25-watt incandescent bulb cannot be
seen through a 2-meter dust cloud exceeding 40 g/m3, whereas
the MEC for coal dust is in the range of 60 g/m3. While dust
concentrations approaching these levels are not normally
present in working areas, accumulations of dust, when
disturbed, may result in temporary concentrations of dust above
An example of the the MEC. The accumulation of layers of dust on heat-producing
temperature test electrical equipment, such as motors, can prevent the release
conducted on an of heat from the equipment and may create temperatures hot
Ex-e terminal enough to ignite the dust layer. The burning dust if disturbed
enclosure. can simultaneously create an ignitable dust cloud and an
ignition source, resulting in a dust explosion. Thus, one of the
best methods to avoid dust explosions is to enforce good
housekeeping rules.
Cooper Crouse-Hinds Ex Digest 9
Basics of Explosion Protection
While it was common practice prior to the early 1990s to classify While past practices achieved Zone 2 (Division 2) area
most indoor Class I Hazardous Locations as Zone 1 (Division classification by providing six air changes per hour by
1), many users now believe that most buildings function in mechanical means, recent experience has shown that in many
accordance with the definition for Class I, Zone 2. It is important Class I buildings, “adequate ventilation” often requires less than
to remember that the Hazardous Location definitions in the one air change per hour, and can be provided by the naturally
NEC and CEC are the basic requirements. There are many occurring ventilation. Often the reduced ventilation requirement
other industry documents such as the API Recommended eliminates the need for complicated and expensive ventilation
Practice for Area Classification which are only recommended systems and reduces the energy required to heat the building.
means of meeting the Code definitions and are not Code (Calculation formulas are also given in IEC 60079-10) However,
requirements. Any method that demonstrates compliance with there are many instances where buildings such as pumping
the area classification definitions meets the requirements of the stations are remotely located and not manned on a 24-hour
respective Code. basis. The buildings are designed as Zone 1 to accommodate
any unforeseen problems.
In most buildings the area classification choice is between Zone
1 and Zone 2. In making that choice there are a number of tools
that may be used. If it can be demonstrated that a building is
“adequately ventilated,” it meets one of the main requirements
of a Zone 2 classification. The other requirement for a Zone 2
classification is that in the event of an abnormal gas release
approaching or exceeding explosive levels, action must be
taken to correct the problem within a “short time.” Many
industrial users accept a 10-hour/per year “rule of thumb” limit
on exposure to “explosive gas atmospheres” for Zone 2
Hazardous Locations. If the building is on a site that is
continuously manned, or it is monitored by gas detection to shut
down the process, or alarmed to allow operating personnel to
correct the problem, the requirements for a Zone 2 classification
are often effectively met. Many skid platforms are not manned and are classified as Zone 1.
Article 501.1 of the NEC permits properly marked operation of equipment. A storage room which houses 55-
Class I, Zone 0,1 or 2 equipment to be installed in gallon drums of volatile solvents would be a typical example of
Division 2. a Division 2 location. This classification approximates Zone 2 in
IEC Standards.
3.8.2 ZONE 1
(b) Zone 1, comprising Class I locations in which:
(i) Explosive gas atmospheres are likely to occur in normal
operation; or
Division 1 areas
encompass
Table 3 in paragraph 6.5.8.3 of API-RP505—Recommended
Zones 0, 1 & 2.
Practice for Classification of Locations for Electrical Installations
at Petroleum Facilities Classified as Class I, Zone 0, Zone 1,
and Zone 2, suggests Zone 1 locations are those where there
A Class I, Division 2 location is one where volatile flammable is a flammable mixture more than 10 hours per year and less
liquids or flammable gases are handled, processed or used, but than 1,000 hours per year. Zone 1 locations normally occur
which are normally enclosed in containers from which they can around vents or in enclosed areas where there are
only escape in the case of accidental rupturing or abnormal intermittent or continuously open processes (for example, a
Cooper Crouse-Hinds Ex Digest 13
Area Classification
(iii) Explosive gas atmospheres are normally prevented by Similar to (b)(iii), there will normally be a Zone 2 area
adequate ventilation but which may occur as a result of failure classified around a Zone 1 area surrounding a vent. It is also
or abnormal operation of the ventilation system; or common for there to be a Zone 2 location around enclosed
areas classified as Zone 1 unless there is a “vapor-tight
Adequate ventilation is defined as “natural or artificial barrier” around the Zone 1 area. For example, a process
ventilation that is sufficient to prevent the accumulation of building with doors windows and other openings in the walls
significant quantities of vapor-air or gas-air mixtures in will typically have a Zone 2 area around all or portions of the
concentrations above 25% of their lower explosive limit.” building.
During “normal operation” there are small gas and vapor
releases from various components of the piping system such
as pump seals, valve packing and flange gaskets. These
releases are relatively small in comparison to abnormal
releases due to equipment failures. These releases are
referred to as “fugitive emissions.” Adequate ventilation for an
enclosed area is therefore the amount of ventilation required
to continuously dilute the fugitive emissions in that enclosed
area to concentrations below 25% of their LEL. (In practice it
is uncommon to encounter gas concentrations above 1 or 2%
of LEL.)
ZONE 1
• Areas above roofs outside storage tanks.
• Areas above floating storage tanks.
• Areas within a specified radius around the outlet pipes and
safety valves.
• Rooms without ventilation openings from a Zone 1 area.
• Areas around flexible pipelines and hoses.
• Areas around sample taking points.
• Areas around seals of pumps, compressors and similar
primary sources.
ZONE 2
• Areas around flanges and connecting valves.
• Areas outside Zone 1 around outlet pipes and safety valves.
• Areas around vent openings from Zone 2.
– ZONE 0
– ZONE 1
ZONE 2 –
Flameproof d Withstand and contain the explosion & prevent 1 EN 50 018 60079-1
transmission of explosion to surrounding
external atmosphere.
Intrinsic Safety ia Removes ignition from explosion triangle through 0 EN 50 020 60079-11
ib prevention of high fault current & voltage. 1 EN 50 020 60079-11
Powder Filled q Electrical components are covered with a filling 1 EN 50 017 60079-5
medium, preventing presence of explosive
gas-air mixtures.
Oil Immersion o Electrical parts are immersed in oil, preventing 1 EN 50 015 60079-6
exposure of arc or spark to explosive atmosphere.
4.1 FLAMEPROOF TYPE ‘d’ PROTECTION These devices pass the explosionproof tests because the
DESIGN CONCEPTS internal volume containing the contacts and the gas-air mixture
is very small so the explosive force is limited. The hot gases,
The IEC standards permit routine tests which allow which are minimized, escape through more elaborate labyrinth
Ex-d enclosures to be individually tested at 1.5 times or cylindrical joints. These switches are now widely used in
the maximum pressures. Explosionproof enclosures control stations and panels where the current levels are typically
less than 16 amps.
are tested to 4 times the maximum pressures.
Flameproof enclosures contain the explosion and allow gases to cool as they
escape across the joints.
4.2 INCREASED SAFETY TYPE “e” • Specified creepage distances as detailed in EN 50-019 and
PROTECTION DESIGN CONCEPTS IEC 60079-7 for the grade of insulation material (CTI) and
subsequent maximum voltage rating.
The increased safety concept is only suitable for • Temperature limitation,
nonsparking apparatus and is commonly used in • Current de-rating of the terminals (and conductors)
Zone 1 designated hazardous areas.
Cooper Normally air is the protective gas used provided that the oxygen
Crouse-Hinds offers content is not more than 21%. Alternatively, an inert gas such
grounded as nitrogen may be used.
and isolated
intrinsically safe
barriers in addition to
intrinsically safe I/O.
See Chapter 9 for
complete details.
There are few limitations on the types of electrical components Type “n” is very similar to nonincendive that has been used by
that can be protected by the pressurized concept. Some typical North American manufacturers for many years, but only
applications for pressurization include analyzer rooms, offshore recently has the IEC begun to develop guidelines on how to
oil platform accommodations, large (high voltage) rotating apply this technique. IEC 60079-15 defines requirements for
machines and instrument panels. To prevent the ingress of this equipment. Present thinking within the IEC is that
flammable materials, the pressurized gas must be carefully certification will not be required for Zone 2 equipment as it is for
controlled, requiring accurate pressure control systems for both Zones 0 and 1. While this will be a cost savings for everyone, it
pressure and flow measurement. If the pressure fails or, the remains to be seen whether the users will accept self-
purge cycle has not been completed, the pressurized enclosure certifications.
must be “volt free,” meaning power is disconnected to the
enclosure. Although the basic principles of pressurization are Contained within the Type “n” guidelines are the following
simple, the practical aspects are usually considerably more definitions of hazardous area protection.
complex.
Enclosed-break devices—These devices are applied when
energy is limited. They have small internal volume, use resilient
4.5 NON-SPARKING TYPE “n” PROTECTION gasket seals, and are subject to ignition testing similar to a
DESIGN CONCEPTS Westerberg test, i.e. the device is put in a box and both the
device and the box are filled with a flammable mixture. The
Present thinking within the IEC is that certification will device is operated with maximum rated voltage and current and
not be required for Zone 2 equipment as it is for if no damage or external ignition occurs, the device passes the
Zones 0 and 1. test.
Nonincendive components—Energy is limited and external
ignition may not occur.
4.5.1 NONSPARKING TYPE “n” PROTECTION
For Zone 2 applications there is an option different from Zone 1 Hermetically sealed devices—Reliability requirements are
referred to as a type of protection “n,” sometimes called “Ex-n” applied to fusion seals.
or nonsparking. Type “n” apparatus is standard industrial Sealed devices—Requirements cover construction and
equipment which in normal operation will not produce arcs, resilient gasket seals.
sparks or surface temperatures high enough to cause ignition.
Energy limited apparatus and circuits—This is similar to
The apparatus has an IP rating called Ingress Protection which
North American nonincendive, except that the device and
is similar to NEMA enclosure ratings such as NEMA 4,
circuits need not be tested with ground faults or short circuits.
hosetight. A nonincendive component is limited in use to the
particular circuit for which it has been shown to be non-ignition
capable. Unlike intrinsic safety, there is no restriction on the 4.6 POWDER FILLED TYPE “q” PROTECTION
energy levels. DESIGN CONCEPTS
Powder filled, Ex-q, protection method is generally
only used for small transformers, capacitors and on
electrical components that have no moving parts.
Ex-n prevents or
limits electrical 4.6.1 POWDER FILLED TYPE “q”
apparatus sparking PROTECTION
in Zone 2. Powder filling originated in France as a concept in 1954, but it
was not generally recognized as an Ex Protection concept until
4.5.2 Ex-n APPLICATIONS the publication of IEC Standard 60079-5 in 1967.
Refer to Appendix 6 for more details on non-sparking.
For particular types of equipment such as motors and This protection method is typically only used for small
receptacles detailed requirements are applied: transformers, capacitors and on electrical components that
have no moving parts. The protection consists of a sealed
• Motors must have secure rotor bars and fans, ventilation enclosure (normally with a vent) containing quartz sand (the
screens, adequate clearances and tight terminal boxes. origin of the “q” description), powder or glass beads.
• Plugs and receptacles must be of the locking type, designed
so incorrect connection is not possible, and labeled, “Do Not
Disconnect When Energized.”
• Luminaries may be incandescent, fluorescent, or other high
intensity discharge lamp except for low-pressure sodium, but
must be marked with the lamp rating and information relevant
to the temperature class. Lamps must be enclosed,
nonsparking, and meet other safety requirements.
Cooper Crouse-Hinds Ex Digest 21
Methods of Protection
The enclosed electrical components are covered and The Ex-q concept was
surrounded by the filling medium. This ensures that under originally used for the
normal use no arc can be created which is able to ignite the electronic ballast in the
exposive mixture inside the enclosure and the surrounding SpecOne eLLK
hazardous area. fluorescent luminaries.
(The ballast was
redesigned in 1992 to the
Ex-d design.) If these
devices fail, they are
replaced “like for like”
from the original
manufacturer as a
Ex-q surrounds certified spare part. The
electrical user cannot repair them..
apparatus in sand.
4.7 OIL IMMERSION TYPE “o” PROTECTION
DESIGN CONCEPTS
4.6.2 Ex-q APPLICATIONS
This protection concept is normally suitable up to and including There are very few examples of Ex-o certified
Group IIC gases and the T6 temperature classification, in Zone products installed in hazardous areas even though
1 or 2 hazardous area locations. the standards permit its use in Zones 1 and 2.
The enclosure construction requirements are a pressure test of
0.5 bar (1 bar = 14.5 psi) over-pressure for 1 minute and, if not 4.7.1 OIL IMMERSION TYPE “o” PROTECTION
protected by another enclosure, a minimum Ingress Protection The Oil Immersion Ex-o concept has historically been used for
of IP 54, the same requirement for Ex-e enclosures. If the q- heavy duty switchgear, motor starters and transformers. The
component is protected by another enclosure (e.g. a capacitor standard for design and testing of Ex-o type electrical apparatus
in the type of protection “q” built into a light enclosure) then no is IEC 60079-6.
specific requirements for the type of IP protection is required.
When the enclosure is filled with the “q” medium (quartz sand,
powder or glass beads) there must be no voids in the Ex-o immerses
enclosure. electrical
apparatus in oil to
The maximum distance from live parts of electrical components prevent arcs or
to earth fitted inside the metal enclosure or metal screen is sparks from
specified and, depending on the applied voltage, can vary from igniting volatile
10 mm at 250 volts to 50 mm at 6,600 volts. If the enclosure is gases.
permanently factory sealed and the voltage does not exceed
500 volts, the minimum distance between live parts or live parts The basic principle as shown above is to immerse the electrical
to earth can be reduced by 5 mm. parts in mineral oil, which will prevent any exposure of the
arcing or sparking to the an explosive atmosphere. It will also
If there are “flying leads” from the apparatus, they must be quench arcs and limit the temperature rise on electrical parts.
connected to Ex-e certified terminals.
Standards for oil immersion protection, Ex-o, require that all
parts capable of producing arcs or sparks must be immersed in
the oil at a depth not be than 25 mm. A method to check the oil
level must be provided, e.g., by a sight glass or by some other
reliable method.
Brazil CEPEL
Canada CSA
UK Baseefa2000, SIRA, EECS
Norway NEMKO
Sweden SEMKO
Denmark DEMKO
Holland KEMA
Germany PTB, DMT, TUV
France LCIE, CERCHAR
Spain LOM
Italy CESI
Australia SAA
Japan JIS
South Africa SABS Flameproof enclosures normally have a component certificate.
Figure 5.5
Hose Test Data Flow (UL 50 vs. UL 595).
18
16
§
14
12
Pressure (PSI)
10
4
•
2
0
0 10 20 30 40 50 60 70 80 90 100 110 120
Gallons Per Minute
The SpecOne eLLK fluorescent luminaries meet the Shell Deluge test.
The most common application of marine grade light fixtures are the FMV
and F2MV floodlights which are also suitable for Division 2.
To simplify markings, CENELEC should drop the E in
5.3.3 SHELL DELUGE TEST: EEx while the U.S. drops the requirement for A in AEx.
This test originated with the Shell UK Exploration and The NRTL logo should indicate to users that the product
Production LTD and was designed to simulate emergency meets the national standards.
deluge testing for electrical equipment in offshore locations. The
objective of the test is to ensure that exposure of equipment to
severe conditions will not lead to water ingress in quantities that 5.4 APPROVAL MARKINGS
could cause equipment to become a potential source of ignition Many industrial end users and manufacturers wanted a
when exposed to a flammable atmosphere. It covers harmonized international standard so a new plant built offshore
fluorescent luminaries, floodlights, terminal boxes and motors. would have the same equipment and installation standards as
After the fixtures reach normal operating temperatures, they are one built domestically. This would allow them to take advantage
subjected to cold salt-water spray. The fixtures must have less of a single sourcing of materials and less expensive alternatives
than 5 ml of water present inside and continue to meet not always available elsewhere. Manufacturers will develop
prescribed insulation tests. (See Appendix 5 for the test products that can be sold into any market with little if any
requirements.) modifications. End users will use one design team with one set
of suppliers working to meet one global standard. Despite the
common goal to standardize electrical codes, the present
course of actions for the NEC and CEC, have made this
impractical. For example, the U.S., Canada, ATEX and
CENELEC each have different nomenclature and
requirements. A typical label designating that the hazardous
area equipment meets North American, IEC, and CENELEC
approvals would contain the information shown in Table 5.5.
The directive 94/9/IEC, also known as the ATEX ATEX was intended to encourage new products with explosion
directive, allows performance testing which protection techniques outside the boundaries of the EN
should encourage new protection techniques. It standards, and to avoid the lengthy approval process ending in
leaves the construction details up to the manufacturer. a so-called inspection certificate. It leaves the construction
details up to the manufacturer. This places responsibility of
documenting and certifying the equipment on the manufacturer,
5.5 ATEX—THE NEW EUROPEAN APPROVAL thereby eliminating the usual Certificate of Conformity or
PROCESS Inspection Certificate.
See Appendix 6 for a detailed summary.
Before 1978 each European country had its own standard for
Hazardous Location equipment, or it accepted one or more of
the standards from another country. In 1978, the first set of
European standards for electrical products for use in hazardous
areas (based on the first EC directive) were issued based on a
collective work of all prior standards for use in all listed
European Community (EC) countries. Only equipment
designed and certified by the authorized bodies to these
standards could be used within the community, regardless of
where the equipment was made.
The Cooper Crouse Hinds GUB and EJB products are certified by PTB to
The last directive, 94/9/EC “Explosive Atmospheres Directive the ATEX directive. The products have an external ground, a cover locking
(ATEX)” covers all equipment that is intended for use in mechanism on threaded covers and additional nameplate markings.
potentially explosive atmospheres. All Hazardous Location
equipment installed and used in the EC must fulfill the essential
health and safety requirements relating to the design and
The CE mark is a manufacturer’s self declaration that
construction of equipment and protective systems intended for the products meet a standard. It is not an approval
use in potentially explosive atmospheres. The manufacturer fof and is only required in the European market.
the equipment may assume that this is the case if it is designed
and certified to harmonize with European Standards or Norms
(EN). This directive became applicable in 1996 and has a 5.5.1 THE CE MARK—NEW MARKINGS,
transition period ending June 30, 2003. After this date all CERTIFICATIONS AND DOCUMENTATION
products used in the EC must conform to the requirements of In 1985, the European Council settled on a new mark, CE,
the ATEX directive. which declares that the apparatus in question meets all relevant
EC directives including essential safety requirements. Under
There are other European directives that must be met. The ATEX the certificate of conformity is replaced by an EC type
EMC (Electromagnetic Compatibility) directive applies to examination certificate. Electrical products intended for Zone 0
Hazardous Location equipment as well as similar industrial and Zone 1 installations still require testing by a third party and
equipment (There are also safety directives for toys). Any a documented quality system by the manufacturer. This implies
product or consumer good sold or used within the EC must that Zone 2 material does not have to undergo third party
meet the directives relevant for that product. Confirmation is testing and approvals, but can be self-certified by the
shown by the “CE” symbol on the product label which is the manufacturer. However, it remains to be seen whether the
manufacturers or importers self-certification. Note: The CE is marketplace will require third party testing and approval. The
not an approval mark and has no relevance outside of the EC. deadline is June 30, 2003 when all apparatus must follow the
ATEX directive and have a quality system in place. The CE
In order to obtain CENELEC certification to the ATEX directive, mark is a manufacturers self declaration that the products meet
the manufacturing facility must first have an ISO certified, a standard. It is not an approval and is only required in the
quality system. The facility must undergo a quality system audit European market.
to verify the facility is continually adhering to the ISO quality
procedures, including the special quality requirements which
belong to explosion protection. ATEX defines the basic
technical requirements of equipment and the protection
methods with which the apparatus is brought to market. The
safety levels or requirements are not limited to the existing
European Standards. Electrical apparatus which does not
comply with the European Standards but which provides an
equal level of safety can now be “certified” by a test lab.
Cooper Crouse-Hinds Ex Digest 29
Testing and Approvals
There will probably not be significant construction 5.5.3 ARE IEC PRODUCTS CERTIFIED FOR
differences between Zone 1 & 2 equipment. ZONE 2 ACCEPTABLE IN NORTH AMERICA?
With the U.S. and Canada now testing to IEC standards, what
is the likelihood that products certified to these standards will be
5.5.2 ZONE 2 STANDARDS commercially viable in the CENELEC countries? The answer is
Over 90% of the hazardous areas in North America are probably not much of a chance for the short term since:
classified as Division 2. As Canada and the U.S. move toward
the Zone concept of classifying areas, these Division 2 areas 1. Zone 2 equipment in Europe can be self certified by the
would logically be classified as Zone 2 areas. The trend to Zone manufacturer while in North America Zone 2 or Division 2
2 will also accelerate in the CENELEC countries where most equipment will have to be certified by a third party in order for
hazardous areas are now classified as Zone 1. However, there it to be commercially viable.
is a scarcity of Zone 2 apparatus available in the European 2. The company that imports the material is responsible for
markets. ensuring that the material has the CE mark. This self-
declaration from the manufacturer confirms that the products
Recognizing that Zone 2 is an area in further need of meet the relevant directives such as EMC Electromagnetic
development, in 1990 CENELEC started to write a harmonized compatibility and for the explosion protection.
standard for Zone 2 construction requirements basing the 3. There are still many differences in markings which remain a
requirements on IEC 79-15, BS 5000 and VDE 0165. The first moving target, and
standard was completed in 1997 and then presented to IEC as 4. Ordinary testing requirements differ greatly between
the new edition of IEC 79-15. The main points of the standard countries. This remains a large hurdle.
and the differences between Zone 1 and 2 construction
requirements are shown in Table 5.6.
Table 5.6
Construction Differences between Zones 1 & 2
Description Zone 1 Zone 2
Equipment grouping & surface temperatures EN 50014 & IEC 79-0 No difference
Mechanical Strength 7 joules/4 joules 50% of values in Zone 1*
Aging Procedure E.g. 80°C, 90% relative humidity; Same figures but only 2 weeks
4 weeks followed by -25° C, 24 hr. instead of 4 weeks
Mechanical properties of plastics T1—20 K T1—10 K
Third party certificate Required Not required
Table 5.7
Marking Examples
Mark Group II Zone Apparatus Explosive Material
II 1G Group II Category 1 Zone 0 apparatus G = gases, vapors, mists
Installation
material not
subject to product
standard
Sealing Fitting
Table 5.8
Example of New ATEX markings
Explosion Protected
Apparatus Group
Category
Suitable for Gas
Suitable for Dust
IP rating
Surface Temperature rating
Explosion Protected
Method of protection
Gas Group
Temperature rating
This has given North American users a wider range of products Two entrepreneurs
to select from. Products which are rated for the IEC Zone from Syracuse, N.Y.,
classification system, and are adapted to North American wiring Jesse L. Hinds and
and installation practices can be installed in Division 2. Huntington B.
Crouse, made outlet
boxes for the new
conduit wiring
systems. They coined
the term condulet,
which was a
combination of
conduit and outlet box
as seen in an early
advertisement.
Cooper Crouse-Hinds Ex Digest 35
Selection, Installation and Wiring of Ex Certified Electrical Equipment
In the 1920s when oil refineries were being constructed, there
was a new need for outlet boxes, fittings and fixtures which
would prevent electrical sparks and heat generating products
from causing explosions. The industry came up with the
concept of Division 1 to define these locations where volatile
gases would be present.
Conduit systems
provide
mechanical
protection of
wires and
conductors.
Steel wire
braided cable
is more flexible
than SWA
Crouse-Hinds offers brass, Cooper Crouse-Hinds non-metallic mounting plate on mounting grid offers a
stainless steel, steel and and non-
quick installation method of control stations and switches.
metallic cable glands for
any type of cable or thread.
Table 6.1
Typical Cable Systems by World Region
AREA CABLE TYPE THREAD
TYPE
Canada TECK NPT
North America Metal Clad Aluminum NPT
Central Europe – Unarmored Cable Metric*
Germany
Europe – offshore Steel Wire Braid Metric
Ireland, Norway, Steel Wire Armor Metric
Holland, Belgium, Unarmored Cable
Spain
Italy, Belgium Steel Wire Armor Metric
Unarmored Cable & NPT
Middle East Steel Wire Armor Metric
Crouse-Hinds NCG non metallic cable glands are offered with (Saudi Arabia & Kuwait) Unarmored Cable NPT
NPT or metric males threads for tray and other flexible cables.
Far East Steel Wire Armor Metric
Unarmored Cable & NPT
CIS States Steel Wire Armor Metric
(Azerbaijan, Unarmored Cable
Kazakhstan)
* Metric threads have replaced Panzer gage (PG) threads
Cooper Crouse-Hinds Ex Digest 37
Selection, Installation and Wiring of Ex Certified Electrical Equipment
6.10 TERMINATING NON-METALLIC EX-e The one variable, which usually creates havoc for end users, is
GLANDS holding the tolerance on the cable diameter especially if
Increased safety non-metallic glands must be certified for flameproof cable glands are used. If the diameters exceed the
ingress protection, impact resistance and aging resistance. tolerances of the glands, they may not fit or seal properly which
There are 2 versions, which depend on the use of the glands. could affect the flameproof integrity of the glands.
For installations where the cables are secured, the glands have
lower requirements for strain relief. If the cables are not secured
trumpet glands are used. Their main purpose is to provide strain
relief where bending, twisting or pulling is common.
CHAPTER 7 • Flat machine joints are not allowed for Group A and B gases
FLAMEPROOF ENCLOSURES with explosionproof or for IIC gases with flameproof.
Manufacturers use threaded or spigot joints for Groups A, B or
IIC certifications.
Field drilling of flameproof, Ex-d, enclosures is not
allowed. To maintain the IEC or CENELEC certificate,
these enclosures can only be modified by the Flamepath
Gap
manufacturer.
Flamepath
Table 7.1
Summary of Differences Between Explosionproof and Flameproof
CONSIDERATION EXPLOSIONPROOF FLAMEPROOF
Field Drilling Acceptable Must be drilled by manufacturer
Pressure testing 4 times maximum 1.5 times maximum
Construction Heavier Lighter
Joints Threaded, flat, labyrinth (serrated) Threaded, flat, spigot
Heat rise Not a consideration Factor which limits components inside
Wiring room Major design consideration Not a major design consideration
Entries Field or factory drilled directly into enclosure Factory drilled directly into
enclosure or field drilled into an
Ex-e enclosure (indirect entry)
Cooper Crouse-Hinds Ex Digest 41
Flameproof Enclosures
Covers on Ex-d enclosures must be secured so they can only be removed with
special tools. The Ex-d flameproof junction box from the Cooper Crouse-
Hinds, Nortem facility in Spain has a hex-head cover locking screw, external
ground and thread openings for conduit or cable.
1. Temperature changes can suck gas/air mixtures into the enclosure
Components not suitable for installation in Ex-d enclosures are
2. When the gas/air mixture is between the the Upper and Lower Flammable
rewireable fuses, devices causing turbulence, oil filled
Limits and a spark occurs, ignition and an internal explosion can occur.
contactors, components containing flammable liquids, liquids or
3. The hot compressed gases are forced out through the flamepath, but must material capable of releasing hydrogen, primary/secondary
not ignite any surrounding external potentially explosive atmosphere. The cells (possible hydrogen release).
flamepath cools the hot, compressed gases as they are expelled, preventing
any explosions of external atmospheres.
7.2.1 FLAMEPATHS & JOINTS IIB VS IIC The pressure inside a flameproof enclosure during an internal
All flameproof joints on enclosure covers or between explosion can rise to 150 PSI (10 bar). There is also the
compartments must be made by one of the following methods: possibility of pressure piling and detonation due to secondary
ignition of compressed gases inside an enclosure, that can
• Flat Joint result in pressures of 450 PSI (30 bar).
• Spigot joint
• Threaded joint Pressure piling is the increase in explosion pressure above
• A combination of all three normal expected pressures caused by the ignition of a pre-
compressed gas. This can result from modifications such as
It is assumed that flammable gases and vapors in the internal sub division of the flameproof enclosure or external
surrounding atmosphere can enter the flameproof enclosure by obstruction adjacent to the flamepath. The static pressure tests
thermal cycling or breathing. A flameproof enclosure is built to requirement for flameproof enclosures are 10 bar for IIA and IIB
withstand the pressure developed during an internal explosion Gas, 15 bar for IIC Gases.
following ignition without damaging the enclosure. In addition to
withstanding an internal explosion, the flamepath width and gap Flat joints can only be used with IIA and IIB gases. Threaded or
in a flameproof enclosure must cool the hot flaming gases as spigot joints are normally used for gas group IIC applications
they pass through the flamepath to prevent ignition of any because of the close tolerance and length of flamepath formed
surrounding explosive atmosphere. by the thread. The minimum number of thread engagements is
not less than 5. The depth of engagement for up 100 cubic cm
The major difference between the explosionproof enclosures is 5 mm and above 100 cubic cm not less than 8 mm. The
used in North America and the flameproof enclosures used in minimum width of joint and maximum gap relative to gas groups
IEC type installations is the construction method. and the enclosure volume are detailed in Table 7.2.1.
Explosionproof enclosures are hydrostatically tested at 4 times
the maximum pressure obtained during explosion tests. If each
flameproof enclosure is tested before it leaves the factory,
called a routine test, it can be constructed to only 1.5 times the
maximum pressure. Because of the difference in testing, Ex-d
enclosures may have lighter construction and the joints may not
be as wide as those on explosionproof enclosures.
Table 7.2.1
Minimum width of joint and maximum gap for enclosures relative to Gas Groups
Gas Group Min. Joint Maximum Gap for Enclosures with Volume
Width (mm) ≤ 100 cm3 > 100 cm3 > 500 cm3 > 2000 cm 3
≤ 500 cm 3
≤ 2000 cm 3
I 6 0.3 – – –
9.5 0.35 0.35 – –
12.5 0.4 0.4 0.4 0.4
25 0.5 0.5 0.5 0.5
II A 6 0.3 – – –
9.5 0.3 0.3 – –
12.5 0.3 0.3 0.3 0.2
25 0.4 0.4 0.4 0.4
IIB 6 0.2 – – –
9.5 0.2 0.2 – –
12.5 0.2 0.2 0.2 0.15
25 0.2 0.2 0.2 0.2
IIC 0 0.1 – – –
9.5 0.1 0.1 – –
Cooper Crouse-Hinds Ex Digest 43
Flameproof Enclosures
7.3 ENTRIES TO FLAMEPROOF ENCLOSURES terminations are made to terminal blocks. Field drilling into the
Field drilling of explosionproof enclosures is a task which Ex-e enclosure is allowed. Outside of Europe the concept of
requires a great deal of care, but is an acceptable practice in indirect entry is not widely practiced. Entries to the enclosures
North America. This is especially welcomed by OEMs, which are made with Ex-d barrier glands, which are sealed cable
may need to modify enclosures in their certified shop to meet glands. Many cable gland manufacturers now have dual Ex-d
local wiring practices. Field drilling of flameproof, Ex-d, boxes is and Ex-e combined certification for their cable gland products.
not allowed. To maintain the IEC certificate, these enclosures
can only modified by the manufacturer. For installers or OEMs
who may need to have additional entries in flameproof
enclosures, it is recommended to order the flameproof
enclosure with extra plugged holes or use the indirect entry
method.
Ex-e increased
safety enclosure
Direct Entry Ex-d IIA and IIB apparatus in Zone 1 and less
than 2 liters in volume.
3. Mix sealing compound and pack Standard Ex-d gland required
conductors over armor.
Direct Entry Ex-d IIA and IIB apparatus in Zone 2.
Standard Ex’d’ required
4. Slide armor stop insert over 7.3.4 MINERAL INSULATED METAL SHEATH
conductor and sealing compound,
then back against armor. Pack
CABLES (MIMS)
remaining sealing compound. When MIMS cable is selected (with or without an outer
protective sheath), the cable gland assembly and “sealing pot”
must be Ex-d certified and installed strictly in accordance with
the manufacturers instruction and certificate “conditions of use.”
This type of cable is often used for fire and gas protection
systems due to its high resistance to temperature and integrity
during a fire.
Most Ex-protected equipment are certified to Conduits terminated in flameproof enclosures must have
temperatures of -20°C. For those regions with more suitable and compatible threads. If the threads are the parallel
extreme temperatures (-45°C), self regulating heaters (metric) type at least 8 axial threads must be engaged. For
can be installed in the enclosures to raise the tapered (NPT) threads at least 5 full threads must be engaged
temperature to the required -20°C. for groups C and D and 7 full threads for Group B.
Use only manufacturer’s specified O-rings as on the Cooper Crouse-Hinds Conduit seals are available from Cooper Crouse-Hinds for the North
Ex-d threaded junction box American market or from Nortem in Spain for ATEX approved seals.
INJECT
70
60
50 =$56
40 =$44
30
20
=$5 =$5 =$5
10
0
1/2" 1" 2"
Sealing Fitting Size
Why spend 50 minutes preparing and pouring a seal whem you can do it easier in five?
Wire nuts are not allowed in Ex-e applications, Each Crouse-Hinds SpecOne terminal box has maximum heat dissipation
tables embossed on the inside cover.
Cooper Crouse-Hinds Ex Digest 51
Increased Safety Type ‘e’ Protection Design Concepts
For instrumentation circuits and other low current applications 8.7 TERMINAL CONNECTION SYSTEM
(not exceeding 8 amps), it is highly unlikely that there will be any The primary function of a connection system is an efficient
significant temperature rise under normal operating conditions. electrical and mechanical connection of the conductor. Ex-e
For power circuits care must be taken not to exceed the terminals employ a clamping yoke or clamp that holds the
manufacturers installation instructions by following the conductor firmly in the clamping unit. The yoke systems are
manufacturer’s tables of permitted terminal population relative screwed in while the clamp system is referred as cage clamps.
to the load current. Both perform equally well to ensure a secure vibration resistant
connection of conductors.
Figure 2 Figure 4
Ignition Curves - Resistance Thermocouple with Fault
Figure 5
Thermocouple with Barrier
An intrinsically safe barrier will limit the excess voltage and current from
reaching the hazardous side.
The energy from the spark created by the combination of voltage and current
must be below the ignition curves to be intrinsically safe. 9.3 INTRINSICALLY SAFE BARRIERS
There are 3 types of barriers most commonly used:
Consider the ignition curves to demonstrate a point about 1. Zener barriers – passive devices which required grounding
thermocouples. A thermocouple is classified as a simple device. for safety
It will not create or store enough energy to ignite any mixture of 2. Isolation barriers – do not require grounding and contain
volatile gases. If the energy level of a typical thermocouple additional electronics for isolation and signal conditioning, or
circuit were plotted on the ignition curve in (Fig 2.), it would 3. Ex-ia I/O – combines I/O with intrinsic safety into one
not be close to the ignition levels of the most volatile gases in package.
Group A. Is the thermocouple which is installed in a hazardous
area (Fig 3) intrinsically safe? The answer is no, because a fault 9.3.1 GROUNDED ZENER BARRIERS
could occur on the recorder which could cause excess energy Grounded barriers, also referred to as zener barriers, are
to reach the hazardous area, as seen in (Fig 4). To make sure passive devices which contain zener diodes to limit excess
that the circuit remains intrinsically safe, a barrier to limit the voltage, resistors to limit current and fuses. These are the basic
energy must be inserted (Fig 5). building blocks which are contained in all other intrinsically safe
barriers. There is always a voltage drop across grounded
Figure 3 barriers because of the resistors so some selection is required
Thermocouple Installed in a Hazardous Area as well as a ground connection. This selection has been greatly
simplified in recent years as manufacturers make them more
application specific. Grounded barriers are also very versatile
and can be applied in many other applications. If your
application has less than 20 outputs or inputs and grounding is
not a consideration, this may be the best solution.
Signals to and from the hazardous area are made intrinsically safe, processed
by the remote I/O electronics, and transmitted to a memory module through a
communication link. These signals are updated every 5 milliseconds and
stored for the main control system. The intrinsically safe remote I/O system is
connected to the controller by a simple 2 wire or fiber optic link to relay
information back and forth.
These systems are ideal for users, who want to eliminate wiring
from the control system to the I/O and can communicate via a
bus system such as Modbus, Profibus, or Fieldbus.
Crouse-Hinds DIN rail isolation barriers do not require a ground for
protection. Refer to www.isbarriers.com
56 Cooper Crouse-Hinds Ex Digest
Intrinsic Safety
There are 3 solutions that depend on the number of devices The intrinsically safe system must be properly installed and
that need to be protected in the hazardous area ranging from provisions must be made to maintain and troubleshoot it. These
simple passive devices which require grounding, isolated procedures are discussed in detail in Article 504 of the National
devices which do not need a ground, and the intrinsically safe Electrical Code (NEC) and the ANSI/ISA RP 12.6-1987
remote I/O which eliminates hardware and field wiring. Recommended Practice Installation of Intrinsically Safe Systems For
Hazardous (Classified) Locations.
9.4 SELECT THE PROPER PRODUCT FOR
YOUR INTRINSICALLY SAFE APPLICATION 9.5.1 WIRING
Intrinsically safe circuits may be wired in the same manner as
Before selecting the best protection method, examine the mix of
comparable circuits installed for unclassified locations with two
analog and digital signals, whether a ground is available,
exceptions summarized as separation and identification. These
amount of cabling required and space in the control room.
wiring practices are simple and clear; however, they often are
There are enough options available now to simplify the
overlooked and are the source of potential problems.
installation and reduce the system costs.
The intrinsically safe conductors must be separated from all
There are many different products that will make a sensor or
other wiring by placing them in separate conduits or by a
instrument intrinsically safe. Many times selecting the correct
separation of 2 inches of air space. Within an enclosure the
product is troublesome for the first time user. For a complete
conductors can be separated by a grounded metal or insulated
explanation on how to select the proper barrier refer to
partition.
www.isbarriers.com or www.crouse-hinds.com and click on “code
corner.”
A poor grounding system will have multiple ground points, causing potential
grounding loops
9.5.3 GROUNDING
First determine if the intrinsically safe barriers used in the
system are grounded or isolated. The isolated barriers normally
are larger, more expensive, and do not require a ground for
safety. The grounded safety barriers are smaller and less
expensive, but require a ground to divert the excess energy.
The main rules of grounding intrinsically safe systems are:
• The ground path must have less then 1 ohm of resistance
from the furthest barrier to the main grounding electrode.
• The grounding conductor must be a minimum 12 AWG.
• All ground path connections must be secure, permanent,
visible, and accessible for routine inspection. The correct method of grounding should have a single ground connection.
58 Cooper Crouse-Hinds Ex Digest
Intrinsic Safety
10.1 INTRODUCTION
Power is distributed throughout a plant via distribution panels,
which are centrally controlled switch systems for large numbers
of feeder circuits. These panels are used to control lighting,
heating, appliance, heat tracing, motor and similar circuits. The
panels usually house thermal-magnetic circuit breakers that
provide a disconnect means, short circuit protection and
thermal time delay overload protection. Typical electrical circuit breaker panelboard.
10.1.1 PANELBOARD BASICS Lighting panelboards are rated up to 240 volts and
In all industrial facilities, some means is necessary to safely used for lighting, heat tracing and small motors
distribute incoming power to devices that require electricity.
Simply providing a distribution means is not enough. There
Power panels refer to loads up to 480 volts for 3
must also be protection for the individual distribution paths or phase motors
“branches” which is the circuit breaker or fuse.
10.1.2 120 VS 240 VS 480 VOLT RATED
By definition, a circuit breaker is an automatic switch that stops
current in a suddenly overloaded circuit. By mechanical action,
PANELBOARDS
The local power utility uses a series of transformers to lower the
the breaker will turn on or off as needed. It is also designed to
voltages in stages. Single phase systems result from one
open the circuit automatically by “tripping” at a pre-set level or
winding on the primary and one on the secondary side of the
“trip rating.”
transformer. A “neutral” wire is connected to the midpoint of the
secondary winding dividing the output voltage in half. This
Circuit breakers protect the conductors, not the devices ,from
neutral is connected to the earth (ground) at the transformer.
damage due to overloads and/or short circuits. (The devices
This arrangement provides two voltages within a three wire
can be protected by an internal circuit breaker with a reset
system. It is still considered a single phase system even though
feature as found on hair dryers.) In a residence these devices
two voltages are supplied.
or loads would be permanent lights, electric ranges, air
conditioners and other, devices plugged into convenience
outlets such as: radios, televisions, etc. Industrial examples
requiring circuit breakers include: motor operated valves,
pumping stations, heat tracing circuits, lighting systems,
conveyor lines, etc. Combining distribution and circuit protection
in one device results in the “electrical circuit breaker
panelboard.”
Advantages Other Considerations • Panels should be factory sealed to avoid the added cost of
Modular design for Must use explosion pouring explosion proof seals.
small panels or protected breakers • A fully wired terminal housing including ground bar and solid
very large panels neutral makes installation easier since the circuit breaker
Available in nonmetallic, Adding breakers housing is closed for field wiring.
• Make sure panels can accommodate a large supply of
NEMA 4X, IP 66 housing in the field is more
conductors to eliminate the need to pull additional wires for the
difficult
future electrical requirements.
Breakers can be directly Different breakers • Breakers and operators should be easy to add or change out.
viewed & operated required for • The panel board design will accommodate top and bottom
IEC vs. NEC/CEC entries for the incoming power.
applications • The panel should have quick-release, spring-loaded, and
Suitable for CEC, NEC captive cover bolts.
or IEC applications • The self-aligning circuit breaker operators should self align the
Available with main door mounted operator mechanisms.
disconnect switches up to • To guard against corrosion the panel should be non-metallic or
180 amps copper-free aluminum with stainless steel hardware and O-
rings and breathers and drains.
• Order extra drilled, tapped and plugged openings for future
wiring.
• The panel should include a lifting bracket, removable
mounting feet and hinges.
Cooper Crouse-Hinds D2Z panels have • Make sure the panel has the necessary third party approvals
explosion-protected, Ex-ed, breakers in and hazardous area ratings.
non-metallic, NEMA 4X, IP66
enclosures.
CHAPTER 11
MOTOR DISCONNECTS AND SAFETY
SWITCHES
The UL 98 standard for motor disconnects requires a
larger distance between phase terminals, which
prevents most of the smaller, less expensive rotary
switches from meeting this requirement. As a result
most rotary switches are approved to UL 508
and listed as controllers.
11.1 INTRODUCTION Cooper Crouse-Hinds offers both industrial and explosion protected motor
Motor disconnects and safety switches are used to isolate disconnect switches.
and disconnect the electrical power of electrical installations
during maintenance, cleanings and repair work. 11.3 HORSEPOWER RATINGS OF SWITCHES
The horsepower rating of the switch determines the size of
the motor that the switch can be used with. The North
American standard is UL 98 while the IEC is the motor switch
capacity of AC3 according to EN 60 947-4-1. This standard
requires that switches be capable of switching 10X rated
current in the ON position and 8X current in the OFF position
up to 50 switching cycles. The AC3 switching capacities are
often times rated in kilowatts which can be converted to
horsepower using the conversion 1 kW = 1.36 HP.
The Cooper Crouse-Hinds GHG 26 Series, nonmetallic 10 to 180 amp motor Horsepower Testing Requirements
disconnect switches are rated IP 66 and are UV protected for extreme IEC vs NEC
outdoor environments Endurance Test
AC 3 EN 60 947-4-1 UL 98
Test Voltage 1.05% 1.05%
Test Current 2x 1x
Power Factor* 0.45 0.75
Cycles w/locked rotor - 1000 w/locked rotor - 6000
w/out - 5000 w/out - 400
Flameproof
Current load time 0.05 sec. Not fixed
motor with
nonmetallic Time Btwn. loads 10 sec. 6 cycles/min.
disconnect switch (10 sec. @ 60 Hz)
for Zone 1
Locked Rotor Test
applications.
Test Voltage 1.05% 1.05%
Test Current 8x 5x
11.2 EXPLOSION PROTECTED DESIGN
Because the function is to switch off the electrical supply, the Power factor 0.45 0.45
opening and closing of contacts will create an arc or spark. The Cycles 50 50
most common method is to make the switch itself explosion
Current Load Time 0.05 Not fixed
protected using a flameproof housing and increased safety
terminals Ex-de. The Ex-de switch can then be mounted in a Time Between Loads 10 sec. 6 cycles/min.
non-metallic or general-purpose enclosure suitable for the area (10 sec. @ 60 Hz)
as opposed to an explosionproof enclosure. The switch and *The lower power factor will result in a higher inductance, making this
enclosure are usually designed together to minimize the size of particular test under the EN standard more difficult
the installation.
Cooper Crouse-Hinds Ex Digest 63
Motor Disconnects and Safety Switches
The SpecOne
series of safety
switches are
rated according
to the AC3
switch capacity.
Converting the AC3 switch capacity (kW) values to horsepower ratings provides the following ratings for the Zone 1
nonmetallic disconnect switches.
11.4 UL 98 VS UL 508
According to NEC 430-101 there must be a disconnecting
means capable of disconnecting motors and controllers from
the circuit. Controllers are defined and grouped together
under UL 508. These include push button stations as well as
most of the smaller disconnect switches on the market today.
The disconnecting means must be located within sight of the
controller.
For the smaller sized enclosures full wiring access is provided by the
cut-away cover.
Cooper Crouse-Hinds Ex Digest 65
Motor Disconnects and Safety Switches
In the US and Canada, the NEMA blade configuration Many proprietary pin and sleeve configurations that do not
is standard for lower voltages in residential, commercial and conform to the IEC standards are designed to accommodate
light industrial use up to 250 volt /20 amps. There multiple voltage systems. A plug wired to a piece of equipment
is no national configuration for larger amperages. designed to operate at one voltage system could unintentionally
be plugged into a receptacle wired with an unlike voltage.
Mismatching voltages could cause damage to the equipment or
even personal injury and is not considered safe electrical
practice.
12.5.3 CONTACTS
Discoloration of contact terminations in plugs, receptacles and
cord connectors is usually due to excessive heat and is a clear
indication of a problem that must be corrected before further
use of the equipment. Loose conductor connections, equipment
operated at greater than rated current, too high ambient
temperature, repeated disconnection under load, poor pin to
sleeve contact and too small of a wire size are all possible
contributors to circuit resistance and overheating. All “individual”
wire strands must be contained in the termination area, and the
termination must be tight. Use of a ferrule is recommended for
finely stranded wire.
Plugs should fit firmly when inserted into the mating connector
and receptacle. Insufficient mating force of contacts can result
in contact erosion/pitting caused by arcing of the contacts and
accidental engagement.
T numbers range from T1, the hottest, to T6, the coolest 13.4 RESTRICTED BREATHING
operating temperature. Gases and vapors will ignite at certain
definable temperatures called ignition temperatures. The Use a restricted breathing / nonsparking luminaire to
operating temperature of the fixture, it’s “T-Number,” must be avoid the use of conduit and cable seals.
lower than the ignition temperatures of the hazardous
atmosphere. These ignition temperatures can be found in
Appendix I of the Cooper Crouse-Hinds Ex Digest.
The Cooper Crouse- Hinds eLLK fluorescent light is rated for Zone 1 areas
and is available with battery backup. The eLLK is constructed to IP 66 to
meet the Shell deluge rating (See Appendix VIII). To meet this rating the fixture
is heated for 24 hours and then cooled to create a vacuum. The eLLK is then
subjected to strong jets of water, 1.5 times the normal velocity needed for the
IP66 rating. The Ni-Cad battery backup also powers the light up to 180
minutes should power fail.
Cooper Crouse-Hinds Ex Digest 73
Installation Recommendations for Cold Environments
The Type 4X nonmetallic IEC 309 and Krydon NPJ Series plugs and
receptacles are ideal for power connections in extreme cold environments.
The Champ-Pak™ CPMV series wall pack and Champ® luminaires are
good cold weather options due to the rigid cast aluminum enclosure and
silicone gasket.
14.4 WIRING
In cold environments insulation materials for standard portable
cables and cords can become brittle and are subject to cracking
and breakdown. Use cables and cords that have passed cold
temperature testing.
14.3 LUBRICATION Cooper Crouse-Hinds CGB Series cable fittings and TECK connectors are
In extreme cold temperatures, lubricants used on shafts and
suitable for use with cold weather cables and cords.
bushings can freeze up, making it difficult to actuate switches
and other rotating equipment. In these conditions, avoid the
use of lubricants where possible or use a lubricant with a
suitable cold temperature rating. 14.5 LIGHTING
CHAPTER 15
EXAMPLES OF IEC HAZARDOUS AREA CLASSIFICATIONS
PRODUCT
Flash point . . . . . . . . . . . . . . . . . . . . Below process and ambient temperature
Vapor density . . . . . . . . . . . . . . . . . . Greater than air
*Airflow from pump motor
Taking into account relevant parameters, the following are typical values which will
be obtained for a pump having a capacity of 50 m3/h and operating at a low pressure:
a = 3 m horizontally from source of release;
b = 1 m from ground level and up to 1 m above the source of release;
NOTE – Due to the high air flow, the extent of zone 1 is negligible
Cooper Crouse-Hinds Ex Digest 77
Examples of IEC Hazardous Area Classifications
PRODUCT
Flash point . . . . . . . . . . . . . . . . . . . . Below process and ambient temperature
Vapor density . . . . . . . . . . . . . . . . . . Greater than air
Taking into account relevant parameters, the following are typical values which will
be obtained for a pump having a capacity of 50 m3/h and operating at a low pressure:
a = 1.5 m horizontally from source of release;
b = 1 m from ground level and up to 1 m above the source of release;
c = 3 m horizontally from source of release.
78 Cooper Crouse-Hinds Ex Digest
Examples of IEC Hazardous Area Classifications
PRODUCT
Gasoline gas density . . . . . . . . . . . . Greater than air
Taking into account relevant parameters, the following are typical values which will
be obtained for a valve where the opening pressure of the valve is approximately 0.15 MPa
(1.5 bar):
a = 3 m in all directions from source of release;
b = 5 m in all directions from source of release.
Cooper Crouse-Hinds Ex Digest 79
Examples of IEC Hazardous Area Classifications
PRODUCT
Flash point . . . . . . . . . . . . . . . . . . . . Below process and ambient temperature
Vapor density . . . . . . . . . . . . . . . . . . Greater than air
Taking into account relevant parameters, the following are typical values which will
be obtained for this example:
a = 1 m horizontally from source of release;
b = 1 m above source of release;
c = 1 m horizontally;
d = 2 m horizontally;
e = 1 m above ground.
80 Cooper Crouse-Hinds Ex Digest
Examples of IEC Hazardous Area Classifications
PRODUCT
Flash point . . . . . . . . . . . . . . . . . . . . Below process and ambient temperature
Vapor density . . . . . . . . . . . . . . . . . . Greater than air
Taking into account relevant parameters, the following are typical values which will
be obtained for this example:
a = 3 m horizontally from the separator;
b = 1 m above ground level;
c = 7.5 m horizontally;
d = 3 m above ground level.
Cooper Crouse-Hinds Ex Digest 81
Examples of IEC Hazardous Area Classifications
PRODUCT
Gas . . . . . . . . . . . . . . . . . . . . . . . . . . Propane
Gas density . . . . . . . . . . . . . . . . . . . Greater than air
Taking into account relevant parameters, the following are typical values which will
be obtained for this example:
a = 1 m in all directions from source of release.
82 Cooper Crouse-Hinds Ex Digest
Examples of IEC Hazardous Area Classifications
PRODUCT
Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrogen
Gas density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighter than air
Taking into account relevant parameters, the following are typical values which will
be obtained for this example:
a = 3 m horizontally from source of release;
b = 1 m horizontally from ventilation openings;
c = 1 m above ventilation openings.
Cooper Crouse-Hinds Ex Digest 83
Examples of IEC Hazardous Area Classifications
PRODUCT
Flash point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below process and
ambient temperature
Vapor density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than air
*Within the tank and the sump, low.
Taking into account relevant parameters, the following are typical values which will be
obtained for this example:
a = 3 m from vent openings;
b = 3 m above the roof;
c = 3 m horizontally from the tank.
84 Cooper Crouse-Hinds Ex Digest
Examples of IEC Hazardous Area Classifications
15.9 TANK CAR FILLING INSTALLATION
Outdoors for gasoline
PRODUCT
Flash point . . . . . . . . . . . . . . . . . . . . . . . Below process and ambient temperature
Vapor density . . . . . . . . . . . . . . . . . . . . . Greater than air
Taking into account relevant parameters, the following are typical values which will
be obtained for this example:
a = 1.5 m horizontally from source of release;
b = horizontally to island boundary;
c = 1.5 m above source of release;
d = 1 m above ground level;
e = 4.5 m horizontally from drainage channel;
f = 1.5 m horizontally from zone 1;
g = 1.0 m above zone 1.
NOTE – If the system is a closed system with vapor recovery, the distances can be
reduced, such that zone 1 may be of negligible extent and zone 2 significantly reduced.