Hazardous Area Guide en

Hazardous Area Guide
Hazardous Area
Safety Competence
Mettler-Toledo AG
CH-8606 Greifensee
Switzerland
Tel. +41 44 944 22 11
Fax +41 44 944 30 60
Subject to technical changes

© 09/2014 Mettler-Toledo AG
MarCom Industrial
2 METTLER TOLEDO - Hazardous Area Guide ©2014 Mettler-Toledo AG

Table of Content
Chapter 1 Explosion Protection - Basics 06
Chapter 2 International Standards and Regulations 11
Chapter 3 Hazardous Area Classification 18
Chapter 4 Ignition Protection Methods 28
Chapter 5 Marking of Electrical Equipment 33
Chapter 6 Electrical Equipment - Installation and Maintenance 36
Chapter 7 Weighing in Hazardous Areas 40
Chapter 8 Summary 49
Chapter 9 List of Tables and Figures 50
Chapter 10 References 51
©2014 Mettler-Toledo AG METTLER TOLEDO - Hazardous Area Guide 3

Table of Contents
Hazardous Area Guide
1. Explosion Protection - Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1. Explosive atmosphere and explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2. Prevention of explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. International Standards and Regulations . . . . . . . . . . . . . . . . . . . . . . . .

2.1. Global regulations for electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2. European standards and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3. USA and Canada regulations and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4. IECEx standardization scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5. IECEx, ATEX and NEC at a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6. Regional regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Hazardous Area Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1. Groups, zones, and classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2. ATEX classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3. North American NEC classes / division classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4. Ignition temperature and temperature classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5. Comparison of ATEX and NEC classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Ignition Protection Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1. Intrinsic safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2. Flameproof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3. Increased safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4. Non-sparking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5. Encapsulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6. Pressurized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7. Oil immersion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Marking of Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1. ATEX CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2. NEC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Electrical Equipment - Installation and Maintenance . . . . . . . . . . . . . . .

6.1. Hazardous-area inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2. Types of inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3. Factors to determine periodic inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4. Intrinsically safe equipment inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Weighing in Hazardous Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1. Basic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2. Advanced system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3. Process control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4. Fully integrated process control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5. Optional safe area peripherals communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. List of Tables and Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction
Introduction
Every year in the news there seems to be a major incident resulting from an acci-
dent in a hazardous area. Most of these unfortunate incidents could be prevented
with better planning and the right equipment and maintenance. Even the most well-
meaning companies can easily make mistakes, but in hazardous areas, those mis-
takes can come at high price. Preparation, training on regulatory standards and
using the right equipment is the key for safe production in hazardous areas.
Careful selection of weighing solutions to meet specific process requirements and regulations can be a
challenging task for manufacturers that work within hazardous areas. However, it is essential to work-
place safety as well as measurement accuracy.
This guide explains how to avoid dangerous situations in hazardous areas with compliant equipment
and offers a comprehensive explanation of standards and regulations and methods of equipment protec-
tion. The guide also explains how to correctly install and maintain equipment in hazardous areas and
shows examples of weighing systems for hazardous areas.

1 Explosion Protection - Basics
Explosion Protection - Basics
1.1. Explosive atmosphere and explosion
Most manufacturing and processing industries generate po-

tentially explosive atmospheres using flammable or explosive
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substances, such as flammable gases or vapors, flammable
liquids, combustible dusts, ignitable fibers or flyings. These
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substances can build an explosive atmosphere with oxygen.
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When electrical equipment is used in or around such areas,
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there is always a possibility or risk of fire or explosion. Those
areas are called hazardous locations or hazardous areas.
Explosion
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An explosion is the sudden exothermic chemical reaction of
a flammable or combustible material with oxygen and the
simultaneous release of high energy. Ignition source
Figure 1: Triangle of fire
An explosive atmosphere is a mixture of air (oxidizer) and
combustible material in form of gases, vapors, mists or
dusts, in which - due to an ignition by sufficient energy -
combustion spreads to the entire unburned mixture.
An explosion can take place if the following three components
are present in the air:
1. Flammable or explosive substance

2. Oxygen
3. Source of ignition
1.1.1. Flammable or explosive substances
Flammable or explosive substances may be present in the form of gases, vapors and mist or dust clouds. Each ma-
terial is present in a defined concentration and for a certain period of time. The properties of a dangerous substance
that need to be known include the boiling point and flash point of any flammable liquid and whether any flammable
gas or vapor involved is lighter or heavier than air.
Flammable (explosive) substances can be divided in three groups:

• Flammable (explosive) gas
• Flammable (explosive) liquids / vapors
• Flammable (explosive) solids

Flammable Example Explosive
substance characteristics
Flammable gas Hydrogen, propane, propyl- As the percentage of flammable gas increases, the risk of fire
ene, methane, etc becomes greater. When the concentration exeeds a certain limit,
the air becomes saturated with the gas and ignition becomes
less likely.
Flammable liquids / Acetone, ether, acetylene, An important characteristic of flammable liquids is the flash
vapors benzene, etc. point. Flash point is the minimum temperature at which the va-
por concentration near the surface of the liquid is high enough
to form an ignitable mixture. The higher the flash point of the
liquid, the less the danger of ignition
Flammable solids Dust, fibers, flyings For dusts, information on particle size and density will be
needed, once it has been shown that a particular dust can form
an explosive atmosphere. Often, relevant information is con-
tained on a safety datasheet provided with the product.
Table 1: Flammable substances characteristics
Table 1 describes flammable substances and their characteristics. In order to form a potentially explosive at-
mosphere, the flammable/explosive oxidizer mixture must exist within a particular concentration range known
as the explosive limits. These limits depend on the ambient pressure and oxygen content of the air.
The explosive limits are bound by the Lower Explosive Limit (LEL) and the Upper Explosive Limit (UEL).
100% Vol. Oxygen concentration 0% Vol.
Mixture is too lean to cause Mixture is too rich to

Explosive Mixture
an explosion cause an explosion
LEL
UEL
 Explosion Limit 
0% Vol. Concentration of flammable substance 100% Vol.
Figure 2: Explosive limits diagram
The Lower Explosive Limit (LEL) is the minimum concentration of explosive liquid vapor in air that will support
the propagation of flame, or flame spread, through the entire volume of vapor-air mixture upon contact with
an ignition source. Below this limit, the volume of oxygen is too high and the concentration of the flammable
substance is too low. The mixture under this condition is defined as “lean”. In this case, there is no danger of
combustion.
The Upper Explosive Limit (UEL) is the maximum concentration of vapor in air that will support the propaga-
tion of flame. Above this level, the mixture is too “rich” to cause an explosion. In this case, the concentration
of the flammable substances has reached a defined volume in the air ("rich" mixture) which can no longer
cause an explosion.
The range between the LEL and the UEL is called the Explosive Range. In this range, the flammable air mixture
has the right saturation to ignite the atmosphere.

Combustible Dusts
When solids are processed in industrial environments, such as chemical plants and flour mills, often small
particles are present in the environment in the form of dust or dust clouds. Dust is defined in DIN EN 50281-1-2 as
small solid particles in the atmosphere that are deposited due to their own weight but which remain in the atmo-
sphere for some period of time in the form of a dust-air mixture. Dusts are measured in micrometers (commonly
known as microns or μm). The micrometer is a unit of length equal to 10-4 (0.0001) centimeter or approximately
1/25,000 of an inch. Red blood cells are 8 μm (0.0008 cm) in size; human hair is 50–75 μm in diameter and
cotton fiber 15–30 μm.
Some of the natural and synthetic organic materials that can form combustible dusts include:
• F ood products (e.g. grain, cellulose, powdered milk, sugar ...)
•P harmaceuticals (e.g. vitamins, lactose, starch ...)
•W ood (wood dust, wood flour)
• T extiles (cotton dust, nylon dust)
•P lastics (phenolics, polypropylene)
•R esins (lacquer, phenol-formaldehyde)
•B iosolids (dried wastes from sewage treatment plants)
•C oal and other carbon dusts
Combustible dusts can also be formed from inorganic materials and metals including: aluminum, iron, magne-
sium, manganese, sulfur.
For dusts, information on particle size and density will be needed, once it has been shown that a particular dust
can form an explosive atmosphere. Relevant information can be found on a safety data sheet provided with the
product.
1.1.2. Oxygen
Although an explosion usually occurs because of direct presence of oxygen in the mixture, this is not always
true. For example a mixture of the (now seldom used) anesthetic gases, ethyl ether and nitrous oxide, can cause
violent explosions because oxygen is formed from the nitrous oxide.
If the oxygen concentration is above the percentage normally found in the air (21% by volume) flammable limits
are normally exceeded, and the ignition energy is decreased. In addition, the explosion is often considerably
more violent than at normal oxygen concentration in the air.

1.1.3. Ignition sources
This chapter discusses ignition sources related to equipment. These can be hot surfaces, mechanically gener-
ated sparks, electrical apparatuses and static electricity.
• Hot surfaces are a result of energy loss from systems, equipment and components during normal operation.
• Flames and hot gases (including hot particles) can occur inside combustion engines or analysis devices
during normal operation and when a fault has occurred.
• Mechanically generated sparks are produced, for example, by grinding and cutting devices during normal
operation and are not permitted in a potentially explosive atmosphere.
• Electrical apparatuses must normally be regarded as a sufficient ignition sources. Only very low energy
sparks with energies of only microwatt seconds may be regarded as too weak to start an explosion. For this
reason, suitable measures must be adopted to prevent these ignition sources.
• Static electricity. The stored energy can be released in the form of sparks and function as an ignition source.
Because this ignition source can arise independently of an electrical voltage supply, it must also be consid-
ered with non-electrical devices and components. It is connected with separation processes; therefore, these
cases must be assessed where this ignition source needs to be taken into account.
Equipment suppliers reduce the risk of explosion by eliminating ignition sources and by keeping the system’s
active ignition energy at the lowest possible level—lower than the minimum ignition energy. The minimum
ignition energy is the smallest amount of energy required to ignite a combustible vapor, gas or dust cloud. The
minimum ignition energy is measured in Joules.
1.2. Prevention of explosion
To eliminate the risk of explosion, one of the three elements of the “Triangle of Fire” must be removed. Two
possibilities exist to prevent explosions: primary and secondary explosion protection.

1.2.1 Primary explosion protection
Primary explosion protection is based on the concept of prevent-

ing the formation of a potentially explosive atmosphere. These
might include:
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• Using substitutes for flammable substances, for example, in-
st
flammable organic solvents can be substituted with hydrous
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solutions
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• Substituting the oxygen with inert gas, such as nitrogen;
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Triangle
mm
• Using gas detectors
of fire
Fla
• Preventing the formation of explosive atmospheres in hazardous
areas, for example, by means of ventilation.
In the absence of flammable substances, no ignitable mixture Ignition source

will be created. As a result, no explosion risk will exist. This ap-
proach can, of course, only be applied to a limited extent. After
e
all, the flammability of many substances is a desired product
anc
property that is either indispensable or which cannot be con-
st
Ox
ub
trolled, for example, gases and their release in the field of min-
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ing. In such cases, secondary explosion protection measures
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must be taken. Triangle
mm of fire
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1.2.2. Secondary explosion protection

Secondary explosion protection is related to preventing the igni- Ignition source
tion of potentially explosive atmospheres. This means avoiding
sparks (mechanical, electrical, static), flames, hot gases or hot
surfaces, as well as eliminating other possible ignition sources
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anc
such as electromagnetic, ultrasonic etc.

st
Equipment designers are searching for different ways to elimi-

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nate those sources. This can be done by:

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• Using appropriate housing materials, such as stainless steel,

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Triangle
mm
which prevents formation of sparks

of fire
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• Using proper earthing and conducting materials

• Avoiding hot surfaces, e.g. by means of applying intrinsically
safe circuits in the design of electrical equipment.
Ignition source
Figure 3: Explosion protection concepts

2 International Standards and Regulations
International Standards and Regulations
Increasing numbers of accidents in processing industries globally are highlighting the importance for compre-
hensive, harmonized safety regulations and guidelines.
Safety problems related to the design and use of electrical equipment in hazardous areas have led authorities to
impose strict rules. It has also elicited awareness of safe equipment design.
Globally, explosion protection is regulated by the legislatures of the individual countries. National differences in
technical requirements and the required approvals for explosion protected equipment make significant demands,
primarily on global players, and require considerable transparency in development and approval testing.
Standards and mandatory regulations facilitate the free movement of goods by providing a uniformly recognized
framework.
They cover everything from product certification requirements to protective measures for employees who work
with the products. Recognized authorities work to develop uniform standards on both a national and interna-
tional scale. However, historical and country-specific developments have the result that many areas—including
explosion protection—do not yet have a global standard in place.
Country Canada USA USA Europa Russia China Japan Australia

Guideline CEC NEC NEC CENELEC GOST R AQSIQ MHLW IEC
Standard CSA FM UL ATEX GOST R-EX NEPSI TIIS IEC-EX
Figure 4: Global map of guidelines and standards
A basic map of global standards and regulations shows how hazardous-area guidelines and certifications are
distributed around the world (Figure 4).

In Europe, for example, CENELEC has established uniform standards and testing procedures, and the ATEX
Directives provide the requirements for hazardous area safety. In the US, the NEC guidelines and the UL cer-
tification body are relevant. In Australia, it is the IEC and IECEx who create the hazardous-area standards. In
other countries and regions different guidelines and certification bodies are present as can be seen on the
map. However, this guide will focus on the three most relevant standards and directives: ATEX, UL/FM and IEC/
IECEx.
2.1. Global regulations for electrical equipment

There are two major global organizations that set hazardous-area standards globally. One is the International
Electro-Technical CommissionIEC(IEC). This is the premier international standardization
IEC organization for electric,
NFPA
electronic and related technologies. The aim of the IEC is to harmonize the many different standards and regu-
lations throughout the world and to remove trade barriers for related products. For example, the IEC 60079
ATEX
standards are CENELEC
related to the general requirements for hazardous areas. The IEC system ULis and FMin Europe,
followed NEC
Asia, Australia, Africa and some other regions.
PTB DEKRA
The second system is the North American system with the National Electrical Code (NEC) Guidelines, which
are published by the National Fire Protection Association (NFPA).
The requirements for hazardous areas and safety in the workplace are defined in ATEX directives in the Euro-
pean Union and in NEC articles in the USA.
To promote the harmonization of standards, many local regulatory bodies worldwide have totally or partly ad-
opted to the IEC standards. Even the NEC and the Canadian Electrical Code (CEC) are now partly recognizing
the IEC/CENELEC hazardous-areas certification system (Figure 5).
In the following chapters we explore the differences among the standards and their adoption in various coun-
tries worldwide.
IEC NFPA
ATEX CENELEC UL and FM NEC
PTB KEMA
Figure 5: Global view of hazardous standards and regulations
2.2. European standards and directives

To establish requirements and safety standards that are the same throughout Europe, the EC Commission
has compiled product-related “European Directives.” These directives apply to all types of products. The corre-
sponding European standards are developed by the European Committee for Electro-technical Standardization
(CENELEC).
Generally, CENELEC utilizes IEC standards. However, in some cases, CENELEC provides more precise require-
ments. CENELEC does not perform product testing. Other organizations, called “Notified Bodies” (NB), carry

out product testing according to European norms and ATEX directives. There are several “Notified Bodies”
throughout Europe. Two examples are the Physikalisch-Technische Bundesanstalt (PTB) located in Germany,
and DEKRA Certification B.V., located in the Netherlands (Figure 6).
2.2.1. ATEX Directive

ATEX stands for “atmosphere explosibles,” which is the French term for “potentially explosive atmosphere.”
The ATEX Directive was introduced to remove trade barriers within Europe. It is a mandatory legal directive
relying on several forms of conformity assessment. Its purpose is to set a level of safety, which is to be re-
garded as “good enough” to ensure that national authorities would have no reason to prevent free trade within
the European Community.
IEC IEC NFPA
ATEX CENELEC UL and FM NE
PTB DEKRA
Figure 6: European Community standards and directives
The two directives concerning hazardous areas are ATEX94/9/EC and ATEX 1999/92/EC. The directives de-
scribe the equipment and the work environment acceptable within an explosive atmosphere.
2.2.2. The ATEX product directive – 94/9/EC

The ATEX 94/9/EC Directive applies to the manufacture and distribution of equipment and protective systems
intended for use in potentially explosive atmospheres. However, it is being replaced by the substantially
amended Directive 2014/34/EU after a transition period until 2016. The main objective of this directive is to
eliminate or minimize the risks resulting from the use of specified equipment in potentially explosive atmo-
spheres. It specifies the Essential Health and Safety Requirements (EHSRs) relating to the design and con-
struction of the equipment and IEC NFPA
protective systems intended for use in such atmospheres.
Ultimately, it is the equipment manufacturer's

CENELEC responsibility to ensure that the equipment produced and
ATEX UL and FM NEC
certified for use in potentially explosive atmospheres complies with the scope of the above directive.
As such, the manufacturer must PTB KEMA

• carry out a risk assessment
• identify ignition sources
• define the requirements of the equipment to be used inside potentially explosive atmospheres and the con-
trolling devices installed in the safe area contributing to the safe operation; and
• produce and certify the equipment.

2.2.3. The ATEX user directive – 1999/92/EC
The ATEX 1999/92/EC or ATEX 137 Directive is applied for users of equipment in potentially explosive atmo-
spheres. It provides minimum requirements for improving the health and safety protection of workers poten-
tially at risk from explosive atmospheres. The directive is intended to complement ATEX 94/9/EC and offers
health and safety protection for employees in hazardous areas. The directive also applies to the installation
and use of electrical equipment.
The general requirements for employers are to eliminate or control the risks from dangerous substances. In
addition, the directive requires conductinga risk assessment and classification of areas into “Zones” where
explosive atmospheres may occur. This is done according to explosion probability.
Employer obligations
The directive sets out specific obligations that employers must fulfill. At this point, all existing workplaces
must comply with the requirements, which were established June 30, 2003 and went into full effect in June
2006. The manufacturer is required to:
• prevent and protect against explosions
• carry out an assessment of explosion risks
• ensure safe working conditions including the provision of instructions, training, supervision and technical
measures
• classify areas where explosive atmospheres may occur into Zones, including appropriate marking of entry
points into such areas;
• select appropriate equipment and identify possible ignition sources
• prepare an explosion protection document, which is intended to demonstrate that explosion risks have
been identified and assessed and show that adequate prevention and protection measures have been
taken.
2.3. USA and Canada regulations and standards

The basic principles of explosion protection are identical all over the world. However, techniques and sys-
tems have been developed in North America in the area of explosion protection that differ from those of the
IEC (International Electro-technical Commission). While regulations in these countries reveal some differ-
ences in comparison with the IEC system, they also show that there have been attempts at harmonization.
In the USA, all regulations related to manufacturing facilities at risk are found in the National Electrical Code
(NEC) Handbook. The articles 500 to 506 define the requirements for classification of the hazardous loca-
tions and classified hazardous areas in Classes, Divisions and Zones. In the mid-1990s, the American ver-
sion of the IEC / CENELEC Zone system was adapted to the NEC 505 article.
IEC NFPA
UL and FM NEC
Figure 7: USA standards and regulations
A

In Canada, the Canadian Electrical Code (CEC) defines the related regulations. Section 18 and Annex J define
the requirements for hazardous-area classification. The Canadian Electrical Code (CEC) systems accept the
IEC / CENELEC Zone classification system and maintain the class and division standards in the appendix.
2.4. IECEx standardization scheme

IECEx is a single global certification framework based on IEC international standards and it is fast becom-
ing the preferred route for international safe certification of products for use in hazardous areas. It caters to
countries whose national standards are either identical to those of the IEC or very close to IEC standards.
The IECEx certification scheme is a global concept that reduces trade barriers caused by different confor-
mity assessment criteria in various countries and helps the industry to open up new markets by providing a
worldwide certificate.
The scope of IECEx is defined by the standards issued by IEC Standards Committee TC 31. The general re-
quirements for electrical equipment are covered by the IEC EN 60079-0. This defines a precise process for
testing and certifying new products and appoints authorized bodies to carry out these tasks. Added to this,
the certification system has been extended to cover maintenance and repairs for explosion protected equip-
ment. A third area of the IECEx scheme defines the expertise required by specialists working in areas at risks
of explosion.
The IECEx scheme consists of 5 areas:

• IECEx 01: Basic rules
• IECEx 02: Equipment for use in explosive atmospheres
• IECEx 03: Service facilities covering repair and overhaul
• IECEx 04: IECEx conformity mark
• IECEx 05: Personnel competencies
The IECEx Certified Equipment Scheme provides a single International Certificate of Conformity that requires
manufacturers to successfully complete:
• Testing and assessment of samples for compliance with standards
• Assessment and auditing of manufacturers premises
• On-going surveillance audits of manufacturers premises
In addition, it provides a “fast-track” process for countries where regulations still require the issuing of na-
tional Ex certificates or approval. This is achieved by way of global acceptance of IECEx equipment test and
assessment reports.
2.5. IECEx, ATEX and NEC at a glance

A common route to compliance is to use pre-approved products in a specified manner and, if required, a
notified body (for example Baseefa, Sira, TUV) to provide a conformity assessment to gain additional certifi-
cation. Unfortunately, for global export, this is not always sufficient.
An internationally acceptable solution was required to allow equipment designs to be used in any part of the
world without significant modification. The approach would use recognized practice to achieve a common
acceptable level of safety, with the goal of facilitating free trade of hazardous-area use products across all
major world markets.

ATEX NEC/CEC IECEx

Regulatory status Mandatory system Mandatory system Mandatory system
Conformity basis EU-directives (EHSR) US/CN standards IEC standards
e.g. ISA, UL, FM, CSA
Standards EN standards US/CN standards IEC standards
Area classification Zone Zone, Class and Division Zone
Conformity assessor Ex notified bodies (Ex NB) Nationaly Recognized Test- Ex certifying bodies (ExCB)
manufacturer ing Laboratories (NRTL) Ex test labs
(UL, FM, CSA,…)
Issued documents - E C-type examination -Certificate of conformity - Certificate of conformity
certificate -Test report - Test report (ExTR)
- T est report (on request) -Audit report - Quality assessment report
-Q M certificate / report - Online availability all docu-
mentation
Acceptance European Union North America, Canada Australia, New Zealand
Conformity mark
Regional acceptance of Europe, North America, North America, 36 IECEx members states
Technical Report (TR) Japan, Brazil, China Canada, Mexico (status 2014)
Table 2: Comparison of ATEX, NEC/CEC and IECEx
2.6. Examples of regional regulation
2.6.1. China
In China, the certification of explosion-proof equipment is mandatory according to the following laws:
• Standardization Law of PRC
• Product Quality Law
According to those laws, the design, installation, usage, maintenance and rebuild of equipment for hazard-
ous areas must comply with national standards. In the last decade, several new standards were issued on
explosion-protective equipment. Due to the policy of preferential adaptation of international standards, the Ex
standards in China have adapted to relevant IEC standards.
The certification process in China is conducted by several certification bodies including:

• National Supervision and Inspection Center for Explosion Protection and Safety of Instrumentation (NEPSI)
• China National Quality Supervision and Test Center for Explosion Protected Electrical Products (CQST)
• Supervision & Test Center of Ex-products of China Petroleum & Chemical Industry
As an Ex test lab (ExTL), NEPSI accepts IECEx test reports (ExTR) and ATEX reports, and based on that will issue
a national certificate.

2.6.2. Korea
The Korean Agency for Technology and Standards (KATS) is an official representative of the IECEx in Korea.
Similar to other countries, this Korean agency accepts an Ex Test Report (ExTR) and/or an ATEX Report as a
basis for issuing national certification.
There are also several certification organizations in Korea:

• The Korean Occupational Safety and Health Agency (KOSHA) is the national certification organization that
certifies electrical equipment in Korea. It works together with the Korea Electro-technology Research Institute
(KERI) for testing and certification of electrical equipment.
• KERI is a government-sponsored institution and it is approved for testing and certifying domestic and im-
ported electric equipment with an international certification.
Both organizations adopted and follow IEC standards. There are also KTL testing and certification laboratories
in Korea, which provide tests and certification on both national and imported electrical equipment.
2.6.3. Russia
All electrical equipment used in hazardous areas must be certified in Russia and CIS countries as well. To
confirm that equipment is manufactured according to standards requirements and is safe and reliable, it must
undergo an approval procedure.
Certification in Russia is governed by federal laws and legislation. Each CIS country has its own approval
certificates and permissions for operating in hazardous areas. The legal basis for such equipment certification
is "Rules of certification of electrical equipment for explosive atmospheres" (PB 03-538-03). This decree is
published as the Russian Governmental Standards No:28/10 dated March 2003.
In Russia, explosion-protected equipment must comply with GOST R ex-proof standards. The corresponding
certificate is issued by the “Rostest” testing and certification laboratory. However, Russian ex-proof standards
have been harmonized with IEC standards as well as European ATEX 95 and ATEX 137 Directives and relevant
European norms. Russia is a member of the IECEx international certification system. If the equipment is certi-
fied according to ATEX, UL, FM or CSA standards, the verification process to obtain the GOST R Ex-Proof Cer-
tificate of Conformity can be limited to document review with no additional laboratory testing.

3 Hazardous Area Classification
Hazardous Area Classification
3.1. Groups zones and classes

To prevent any risk of explosion or fire and improve safety of the process and employees, all potential hazardous
areas must be classified according to the processes conducted in these areas. It is in responsibility of the end
user to define the hazardous areas within the operations.
Area classification is the method of analyzing and classifying the environment where explosive gas atmospheres
may occur so as to facilitate the proper selection of the electrical equipment. The concept of assessing the po-
tentially explosive areas is crucial to limiting the risk associated with the installation of electrical equipment in
potentially explosive environment.
The assessment tests and appropriate areas classification allows preparation of safety procedures for plant op-
eration and maintenance.
Classification varies across the world, but generally, there are two types of classification:
• European Classification System described by ATEX Directive and
• American Classification System described by National Electrical Code (NEC).
3.2. ATEX group classifications

Europe has adopted the Electro-technical Commision (IEC) philosophy referred to as “Zoning.” Information and
specifications for zone classification are defined in the European Norm IEC EN 60079-10 and in national stand-
ards. Furthermore, the installation and operation of electrical systems in hazardous locations and the zone clas-
sification within the European Community are defined in the ATEX 94/9/EC Directive.
ATEX Directive 94/9/EC deals with the special risk of explosion and has one major aim: to prevent its “own po-
tential source of ignition.”
In order to determine the appropriate conformity assessment procedure, the manufacturer must take a decision,
based on the equipment use, regarding which group and equipment category it belongs to.
The directive defines two equipment groups divided into five equipment categories. Equipment categories define
the required level of protection for equipment.
Zone 1
Division 1
Zone 2
Zone 0 Division 2
Division 1
Equipment Group I Equipment Group II

Zone 0 or 1
Mining Above Surface Industry Division 1
Figure 8: Definition of equipment groups and categories according to ATEX 94/9/EC, respectively NEC500

• Group I equipment applies to equipment used in underground operations, such as mines.
• Group II equipment applies to surface-processing industries. The petrochemical, chemical, pharmaceuti-
cal as well as food industries are typical processing industries.
The equipment groups are further sub-divided into categories as shown in the Table 3. Group I is divided
into categories M1 and M2. Group II is sub-divided into equipment categories 1, 2 and 3.
Category of Hazardous Level of Conditions of operation Performance of

equipment atmosphere ignition protection
protection
Equipment M1 Methane, Very high Equipment remains en- 2 independent protec-
Group I, dust ergized and functioning tion methods or safe
(e.g. mines) when explosive atmo- with 2 faults
sphere is present
M2 High Equipment is de-ener- Sufficient level of safety
gized in the event of an during the normal op-
explosive atmosphere erating conditions
Equipment Cat.1 Gas, vapor, Very high Equipment remains en- 2 independent protec-
Group II, mist, dust ergized and functioning tion methods, or safe
(e.g. pro- in Zones 0,1,2 (G) and/ with 2 faults
cessing or 20,21,22 (D)
industries) Cat.2 High Equipment remains en- Suitable for normal op-
ergized and functioning eration and frequently
in Zones 1,2 (G) and/or occurring disturbances,
21,22 (D) or safe with 1 fault
Cat.3 Normal Equipment remains en- Suitable for normal
ergized and functioning operation
in Zones 2 (G) and/or
22 (D)
Table 3: Equipment group and category classification according to ATEX 94/9/EC
3.1.2. Gas and dust substance group

Up to this point, explosion-proof equipment has been divided into:
• Equipment Group I (underground, for mine workings at risk) and
• Equipment Group II (surface equipment, for areas at risk of explosion excluding mines workings).
Equipment Group II, which is the focus of this guide, draws a further distinction by differentiating between
areas at risk due to gases, vapors and mists and those at risk due to dust. The information in the table be-
low shows the relationships between the gas/dust explosion group and the protection type required in each
case (Table 4).
Explosion group Type of group Characteristics of group

Gas explosion group IIC Easily ignitable (e.g. hydrogen, acetylene)
IIB Ignitable (e.g. coalgas, ethylene, ethylene glycol)
IIA Difficult to ignite (e.g. acetone, benzene, toluene)
Dust explosion group IIIC Conductive dusts (conductivity ≤103Ωm)
IIIB Non-conductive dusts (conductivity >103Ωm)
IIIA Flammable fibers (length >500µm)
Table 4: ATEX substance group classification

3.2.2. ATEX 1999/9/EC zone classification
According to the ATEX 1999/9/EC Directive, Equipment Group II, which is intended to be used in hazardous ar-
eas, is divided into three zones for gases and three zones for dust substances.
The classification given to a particular zone, is made based on the frequency and duration of the occurrence of
the explosive atmosphere (Table 5).
Zone classification
Gas Zone 0 An explosive atmosphere is present continuously or for long periods of time.
Zone 1 An explosive atmosphere is likely to occur occasionally during normal operation.
Zone 2 An explosive atmosphere is likely to occur infrequently or for short periods of time.
Dust Zone 20 An explosive atmosphere is present continuously or for long periods of time.
Zone 21 An explosive atmosphere is likely to occur occasionally during normal operation.
Zone 22 An explosive atmosphere is likely to occur infrequently or for short periods of time.
Table 5: Zone classification according to ATEX 1999/92/EC
This concept has been used successfully for many years for specification and selection of electrical equipment
for explosive gas and dust atmospheres. The zones 0, 1, and 2 are used to denote explosive atmospheres con-
taining gases and vapors. The zones 20, 21, and 22 are the zones containing explosive and flammable dusts.
A methodology for potentially explosive area classification is also available in European Standards EN 60079-10.
The methodology applied in the standards is based on the concept of three “sources of release,” namely con-
tinuous, primary and secondary. Figure 9 shows the classification of the Zones based on the above mentioned
standards.
The processing industries, including petrochemical, chemical and pharmaceutical, are named surface industries
and belong to Group II industries. They may be exposed to gas as well as to dust-laden atmospheres.
The classification of areas with risk of explosion is a rather complex procedure, but it is essentially based on the
identification of the number and type of the emission sources as well as availability of ventilation.
Div 1
Zone 1
Div 2 Div 1
Zone 2 Zone 0
Div 1, Zone 0 or 1
Figure 9: Zone classification according to IEC EN 60079-10 and ATEX 1999/9/EC, respectively NEC500

The classification of hazardous areas is based on the degree of emission:
• Continuous emission generates zone 0/20,
• Primary emission generates zone 1/21, and
• Secondary emission generates zone 2/22
Although there is no fixed rule regarding the presence (duration and probability) of an explosive atmosphere
in relation to zones 0/20, 1/21, 2/22, the table and graphic represent a useful reference.
• For continuous emission, the overall duration of the explosive atmosphere is more than 1,000 hours per
year.
• For primary emission, the overall duration of explosive atmosphere is between 10 and 1,000 hours per
year.
• And, for secondary emissions, this parameter is less than 10 hours per year.
A competent person or certified body must carry out the zone classification process and related explosion-
risk assessment, and determine what protective measures are necessary.
Zone 0 / 20
Risk
Zone 1 / 21
Zone 2 / 22
10 1‘000
Duration of present hazards (hours/year)
Figure 10: Duration and presence of hazards compared to risk (Zone)
3.2.3. ATEX 94/9/EC equipment categories and IECEx equipment protection level
Equipment to be used must correspond to the assigned equipment categories and equipment protection lev-
els (EPL) as prescribed by the zone classification. These equipment requirements are categorised in relation
to the European equipment categories on the basis of EU Directive 94/9/EC (ATEX 95); the EPL, introduced
by the IEC, applies on an international
Division 1 level. Both classifications can be used when marking equipment.
Risk
This classification tells us about the probability of ignition, taking into account potentially explosive gas and
dust Division 2
atmospheres.
Table 6 presents the definitions of equipment categories and equipment protection levels (EPL) and their dif-
ferences. The definition
10
of EPL is usually used in the IECEx marking system (see chapter 5).

ATEX 94/9/EC (ATEX 95) - equipment category IECEx (IEC 60079-0) - equipment protection level
Classification of equipment for use in surface areas at Classification of equipment for use in surface areas at
risk of explosion within Europe divided into three equip- risk of explosion divided into three protection levels for
ment categories for areas at risk of explosion due to gas areas at risk of explosion due to gas (G) or for areas
(G) or for areas with flammable dust (D) with flammable dust (D)
Category 1: 1G or 1D EPL Ga or Da
Very high level of safety. Safe even when rare equipment Equipment with "very high" protection level for use in
faults occur. Two independent explosion protection mea- areas at risk of explosion where there is no ignition risk
sures, even safe when two faults occur independently of during normal operation, or in the case of predictable
one another. or rare faults/malfunctions
Category 2: 2G or 2D EPL Gb or Db
High level of safety. Safe even in the case of equipment Equipment with "high" protection level for use in areas
faults, which occur frequently or which are usually to be at risk of explosion where there is no ignition risk dur-
expected. Even safe when a fault occurs. ing normal operation, or in the case of predictable
faults/malfunctions.
Category 3: 3G or 3D EPL Gc or Dc
Normal level of safety. Safe during normal operation Equipment with "extended" protection level for use in
areas at risk of explosion where there is no ignition
risk during normal operation, and which has some ad-
ditional protective measures, which ensure that there
is no ignition risk in the case of predictable equipment
faults.
Table 6: Definition of ATEX 94/9/EC equipment categories and IECEx equipment protection level
3.2.4. Comparison of ATEX 94/9/EC and ATEX 1999/92/EC

Table 7 shows the comparison between two directives for equipment manufacturers and for users. There is a di-
rect link between the two directives in that the three equipment categories specified in ATEX 94/9/EC correspond
to the three Zones used in ATEX 1999/92/EC for the classification of hazardous areas.
Therefore, in Zone 2/22, equipment category 3 may be used, whereas in Zone 0/20 (explosive atmosphere can
be present continuously), equipment category 1 must be used.
Manufacturer requirements ATEX 94/9/EC User requirements ATEX 1999/92/EC

Definition of area of use of equipment, specification of Risk assessment of hazardous area in working places, em-
equipment group / category ployee safety
Equipment Category 1 Zone 0/20
Comply with essential safety and health requirements Comply with installation and maintenance requirements
or relevant standards
Carry out a risk / ignition-hazard assessment of equipment Carry out a risk assessment of the work place, duty of coor-
dination
Prepare conformity documentation Prepare an explosion document
Appropriate quality control Regular updates
Table 7: Comparison ATEX 94/9/EC and ATEX 1999/92/EC

3.3. North American NEC class / division classification
In the USA, all regulations related to manufacturing facilities at risk are found in the National Electrical Code
(NEC) Handbook. The articles 500, 501, 502, 503 and 505 define the requirements for classification of haz-
ardous locations into Classes, Groups, Divisions and Zones.
According to NEC 500, hazardous locations are divided into Substance Classes I, II, and III depending on the
type of material present. Table 8 shows the classification of the hazardous locations according to NEC 500 -
505 articles.
• Class I locations are those in which flammable gases or vapors are present in the air in quantities sufficient
to produce explosive or ignitable mixtures (NEC 501).
• Class II locations are those in which the dust is present in quantities sufficient for a fire or explosion hazards
to exist. To be considered a “dust,” the combustible material must exist as finely divided solid particles of a
diameter of 420 microns (0.017 inch) or less (NEC 502).
• Class III locations are considered hazardous because of the presence of easily ignitable fibers or flyings
(NEC 503).
Substance Substance Class Area Classification Hazardous location characteristics

NEC500 NEC505
Gases / Class I Division 1 Zone 0 Explosion hazard present continuously or occa-
vapors (NEC 501) Zone 1 sionally under normal operating conditions
Division 2 Zone 2 Ignitable concentrations of flammable gases or
vapors are not normally present, but could be
Zone 0 / 20
Risk
present in the case of a fault

Zone 1 / 21
Dusts Class II Division 1 Zone 20 Combustible dusts are present in quantities
(NEC 502) sufficient to produce explosive and ignitable
Zone 2 / 22 Zone 21
Division 2 Zone 22 Combustible dust due to abnormal operations
may be present in quantities sufficient to pro-
10 1‘000 duce explosive or ignitable mixtures
Fibers Class III (NEC Division 1 Not equiva- Easily ignitable fibers / flyings are handled or
503) lent manufactured
Division 2 Easily ignitable fibers / flyings are stored or
handled
Table 8: Hazardous locations classification system according to NEC 500 – 505
Division 1
Risk
Division 2
10
Figure 11: Duration and presence of hazards compared to risk (Division)

3.3.1. NEC substance group classification
Each class is also divided into the material groups A, B, C, D, E, F and G. Article 500 defines the classification
of the substance classes into substance groups according to their properties and volatility. Table 9 presents this
classification.
The basis for definition of the substance group according to Article 500 is the degree of risk. In this case, it is a
factor of the maximum experimental safety gap or minimum igniting current.
• Group IIC represents very high risk.
• Group IIB represents a high risk.
• Group IIA represents a moderate risk.
Substance Substance class Substance group Substance name

(NEC 500) (NEC 505)
Class I A IIC Acetylene
B Hydrogen
C IIB Ethylene
D IIA Propane
Class II E IIIC Combustible metal dust
F Combustible
G Non-combustible dust
Table 9: NEC 500 and NEC505 substance group classification
3.2.2. American NEC and Canadian CEC zone classification

Article NEC 505 is an alternative classification system to Class II and Class III that is based on the zones of the
International Electrotechnical Commission (IEC) Zones 20, 21 and 22. It applies to combustible dusts or ignit-
able fibers or flyings. Combustible metallic dusts are not covered by NEC article 505.
In Canada, the Canadian Electrical Code (CEC) defines related regulations. Section 18 of CEC and Annex J de-
fines the requirements for hazardous-area classification. The CEC system accepts the IEC/CENELEC Zone classifi-
cation system and maintains Class and Division standards in a separate appendix.
The CEC includes the following rules:
• Rule 18-000 – General Class I, Zone and Class II and III, Division requirements
• Rule 18-090 – Specific Class I, Zone 0 requirements
• Rule 18-100 – Specific Class I, Zone 1 and 2 requirements
• Rule 18-200 – Specific Class II, Division requirements
• Rule 18-300 – Specific Class III, Division requirements
• Appendix J – General and Specific Class I, Division requirements
The NEC and CEC for Canada can be viewed as a starting point from which all subsequent aspects of North
American hazardous Installation Code (Haz Loc) are derived. The NEC codes include all details on equipment
construction, performance and installation requirements as well.

3.4. Ignition temperature and temperature classes
Flammable gases and vapors are classified into temperature classes according to their inflammability. The
ignition temperature of a flammable gas is the lowest temperature of a surface required to ignite a combus-
tible vapor, gas or dust cloud.
The equipment manufacturers are obliged to classify the electrical equipment in the temperature classes de-
pending on the flammable material used. The testing method of ignition temperature is defined by IEC and
CENELEC and summarized in the IEC 60079-4.
Temperature classes from T1 to T6 are defined for flammable gases and vapors as a means of ensuring
safety and protection. In practice, this means that the maximum surface temperature of a material must al-
ways be lower than the ignition temperature of the gas/air or vapor/air mixture. Increasing temperature class
numbers correspond to lower surface temperature of the equipment.
Of course, equipment classified in a higher temperature class (e.g. T5) may also be used for applications in
which a lower temperature class is required (e.g. T2 or T3). In North America, there is a system incorporating
further classification according to temperature subclasses (Table 10).
Ignition temperature Maximum surface NEC 500 CENELEC / NEC 505

gases and vapors temperature
>450°C 450°C T1 T1
>300 to 450°C 300°C T2 T2
>200 to 300°C 280°C T2A -
260°C T2B -
230°C T2C -
215°C T2D -
>135 to 200°C 200°C T3 T3
180°C T3A -
165°C T3B -
160°C T3C -
>100 to 135°C 135°C T4 T4
120°C T4A -
100°C T5 T5
>85 to 100°C 85°C T6 T6
Table 10: Ignition temperature classes
For example, hexane, a common solvent in chemical production, ignites at 240°C. Therefore, equipment used
in an environment in which hexane is present must have a rating of at least T3, because T3 has a defined
maximum of 200°C, which is lower than hexane’s ignition temperature.
Of course, a T4, T5 or T6 rating would also work because all of them have maximum temperatures less than
the ignition temperature of hexane.

Substance Temperature class

Group
T1 T2 T3 T4 T5 T6
I Not relevant for weighing equipment
IIA Acetone Ethanol Benzine Acetylaldehyde
Ethane i-Amyl acetate Diesel fuel Ethyl, ether
Ethyl acetate n-Butane Aviation fuel
Ammonia n-Butil alcohol Domestic fuel
Benzene (pure) Oils
Acetic acid n-Hexane
Carbon monoxide
Methane
Methanol
Propane
Toluene
IIB Ethylene Carbone
disulphide
IIC Hydrogen Acetylene Hydrogen disulphide
Table 11. Temperature classes vs. substance group system
3.5. Comparison of ATEX zone system and NEC classes/division classification

To facilitate the understanding of the differences and similarities between the two systems used in Europe
and North America as well as in other parts of the world, the following diagram shows the correlation and the
differences between these two systems. Both systems are valid and are developed independently from each
other. Each system has its own approach to area classification and each has its own advocates and approval
organizations. Currently, the zone system has wider use globally in the chemical and petrochemical industry.
The NEC class/division system is the dominant method in North America. This method is straightforward, with
little interpretation as to the classification and what electrical materials can or cannot be used. On the other
hand, the zone system offers more choices how to handle particular applications that can make it also more
complicated.

What type of hazardous area classifications

and protection does your company use?
NEC CEC standards ATEX /IECEx standards
What type of hazardous substances What type of hazardous

may be present? substances may be present?
Class I Class II Class III

Zone 0, 1, 2 Zone 20, 21, 22
Gas and Dust Fibers and
Gas and vapors Dust
vapors flyings
How often may hazardous substances How often may hazardous substances
be present in the atmosphere? be present in the atmosphere?
Are likely to exist Are NOT likely to exist Continuously present Are likely to exist Are NOT likely to
under normal operating under normal for long periods of under normal exist under normal
conditions operating conditions time under normal operating conditions operating conditions
operating conditions
Class I Class, II, III Zone 0: Gas & vapors Zone 1: Gas & vapors Zone 2: Gas & vapors
Gas and vapors Gas and vapors Zone 20: Dust Zone 21: Dust Zone 22: Dust
Figure 12: Comparison NEC and ATEX /IECEx class and zone classification system

4 Ignition Protection Methods
Ignition Protection Methods
The basic safety concept is to eliminate the simultaneous existence of possible ignition sources. The method
of equipment protection will likely depend on the degree of safety needed for the type of hazardous location.
Besides the degree of safety required for the classified area, other considerations must be made, such as the
size of the equipment, its normal function, power requirements, installation costs and flexibility of the protection
method for maintenance.
Table 12 shows an overview of the standardized types of protection. It describes the basic principle of each pro-
tection method as well as the applicable standard and the classified area. The protection methods are standard-
ized and the standards vary in different countries. However, the principles of protection are the same regardless
of the country. When it comes to designing and developing weighing equipment for hazardous areas, the intrin-
sic safety and flameproof methods are mainly applied.
Protection Marking Principle Standard Area classification

type EU USA IEC / EN USA CSA Zone(s) Division
(ATEX (NEC
94/9/EC) 500)
General Ex AEx Basis for protection 60079-0 FM 3600 CSA C22.2
Regulation type UL 60079-0 #60079-0
Intrinsic Ex ia AEx ia Limit energy; no sparks 60079-11 FM 3610 CSA 0, 1 and 1 and 2
Safety or hot surfaces UL 60079-11 E60079-11 2
Ex ib AEx ia 1 and 2
Ex ic 2 2
Flameproof Ex d AEx d Contain the explosion, 60079-1 ISA 60079-1 CSA 22.2 1 and 2 1 and 2
quench the flame UL 60079-1 #60079-1
Increased Ex e AEx e Dust / water 60079 -7 ISA 60079-7 CSA 1 and 2 1 and 2
Safety tight enclosure UL 60079-7 E60079-7
Non- Ex nA AEx nA No sparking device 60079-15 ISA 60079- CSA 2 2
Sparking Ex nC AEx nC Sparking devices and 15 UL 1203 E60079-15
components
Encapsu- Ex m AEx m Keep the explosive 60079-18 ISA 60079- CSA 0, 1 and 1 and 2
lation atmosphere away from 18 UL E79-18 2
any source of ignition 60079-18
Pressurized Ex p AEx p Purge enclosure with 60079-2 FM 3620 CSA 1 and 2 1 and 2
inert pressurized air UL 60079-2 E60079-2
Oil Ex o AEx o Keep the explosive 60079-6 ISA 60079-6 CSA 1 and 2 1 and 2
Immersion atmosphere away from UL 60079-6 E60079-6
the ignition source
Table 12. Protection methods and related standards

4.1. Intrinsic safety – “Ex i”
Since it was introduced in non-mining applications,
intrinsic safety has evolved to become one of the most
commonly used protection methods in process indus-
tries. Today, intrinsic safety is one of the safest and most
advanced methods of ignition protection. It has become
the method of choice because, independent from the
application, it keeps the entire system safe. Intrinsically
safe technology prevents explosions by ensuring that the
energy transferred to a hazardous area is well below the Figure 13: Intrinsically safe enclosure
energy required to initiate an explosion. As such, it is re-
stricted to electrical apparatuses and circuits in which the
output or consumption of energy is limited. Intrinsically
safe systems enable equipment to be used without risk of
igniting any flammable gas, dust or fibers that may pre-
sent in hazardous areas.
Intrinsic safe circuit

An electrical circuit is intrinsically safe when it pro-
Hazardous Area Safe Area
duces energy below the minimum ignition energy
R Isc
(MIE), which is defined by the appropriate stand-
ards. In Europe, IEC EN60079-11 specifies the con-
struction and testing of intrinsically safe equipment;
in the USA, FM3610 does this. Intrinsically safe
electrical equipment is designed to limit the open V
Voc
circuit voltage (Voc) and the short circuit current (Isc)
to keep the produced energy at the lowest possible
level. It also must be done in such a way that sparks
produced when opening, closing or earthing the
circuit, or produced by any other hot part of the cir-
Figure 14: Intrinsically safe circuit
cuit itself, would not cause ignition. Intrinsically safe
electrical equipment and wiring can be used in Zone
1/Division 1 hazardous areas as long as they are
approved for the location.
Intrinsic safety classification and protection levels

Intrinsic safety offers three classification levels, "ia," "ib" or "ic," which are based on the safety level and
number of faults possible. Each classification attempts to balance the probability of an explosive atmosphere
being present against the probability of an ignition occurring. The level of protection "ia" is a prerequisite for
Category 1 equipment and is suitable for use in Zone 0. The level of protection “ib” for Category 2 equipment
is suitable for use in Zone 1/Division 1. The level of protection "ic" for Category 3 is suitable for use in Zone 2/
Division 2.

The classifications ensure that the equipment is suitable for an appropriate hazardous application. For exam-
ple, having equipment classified as "Ex ib" means that the equipment is designed containing an intrinsically
safe circuit and can be installed in the certified hazardous areas Zone 1/Division 1. Moreover, the "ib" classifi-
cation indicates that one fault is possible.
Equipment classified as "[Ex ib]" or "Ex [ib]" is defined as an associated electrical apparatus and contains
both intrinsically safe and non-intrinsically safe circuits. The square brackets indicate that the associated elec-
trical apparatus contains an intrinsically safe electric circuit, which may be introduced into Zone 1/Division 1.
In the first case, "[Ex ib]," the equipment must be installed in the safe area. In the case of "Ex [ib]," the equip-
ment can be installed in both Zone 1/Division 1 hazardous areas and in the safe area.
However, it is also possible for different parts of the system to have different levels of protection. Table 13 pre-
sents different protection levels, the numbers of faults possible and the appropriate hazardous area.
ai ib ic
Hazardous area Zone 0,1,2 / Division 1 Zone 1,2 Zone 2 / Division 2
Faults possible 2 1 Normal operation
Table 13: Intrinsically safe protection levels
Some terms and definitions for intrinsically safe equipment are shown in the table below.
Term Definition
Intrinsically safe circuit A circuit in which no spark and no thermal effect can cause the ignition of a potentially
explosive atmosphere
Intrinsically safe electrical All circuits of electrical equipment are intrinsically safe.
equipment The Voltage and the current in the intrinsically safe circuit are low enough such that a
short – circuit, interruption or short – circuit to ground will not ignite the potentially ex-
plosive atmosphere. Intrinsically safe electrical equipment is suitable for operation direct
in hazardous area Zone 0, 1, 2 / Zone 20, 21, 22 and division 1.
Typical marking: Ex ib IIC
Associated electrical At least one circuit of the associated electrical equipment is intrinsically safe. Sensors
equipment connected to the intrinsically safe circuit can be located in the hazardous area. How-
ever the associated electrical equipment must not be located in the hazardous area
without further protection types. The type of protection is placed in the square brackets.
Typical marking: [Ex ib] IIC
Minimum ignition energy The minimum ignition energy is the smallest possible electrical energy required to ig-
nite a combustible vapor, gas or dust cloud. The minimum ignition energy is measured
in Joules.
Table 14 . Terms and definitions for intrinsically safe equipment

4.2. Flame Proof - “Ex d”
The flameproof protection method is based on the explosion-
containment concept and is in accordance with IEC EN60079-1
classified as "Ex d." This concept relies on equipment and wiring
enclosures to prevent an internal ignition from escaping to the sur-
rounding atmosphere. In other words, the explosion is allowed to
Ex d
take place, but it must remain confined in the enclosure that is de-
signed to resist the excess pressure the internal explosion causes. Figure 15: Explosion proof enclosure
The theory supporting this method is that the resultant gas jet com-
ing from the enclosure is cooled rapidly through the enclosure’s
heat conduction and the expansion of the gas. The hot gas is then
diluted in the colder external atmosphere. That is only possible if
the enclosure openings or interstices have sufficiently small and
well-controlled dimensions.
A flameproof system is generally considered somewhat simpler to
design than an intrinsically safe system, as it doesn’t require com-
pletely new equipment design. However, it is generally more expen-
sive to install because of the high cost of running field wiring inside
a conduit, which must be sealed between the safe and hazardous
areas. It is also often physically larger and much heavier than an
intrinsically safe solution.
Flameproof equipment is also more difficult and time-consuming to
maintain because either the area must be known to be non-hazard-
ous or the equipment must have the energy drained before covers
can be removed. Hot permits are required to perform maintenance
work on these systems. Further, when covers are re-installed, extra
care must be taken that fasteners are precisely torqued to specified
values.
4.3. Increased Safety - “Ex e”

The principal of increased safety is to ensure reliable prevention of
unacceptably high temperatures and sparks or electrical arcs. The
equipment usually has a maximum voltage, which is rating to 11 kV.
The basic design requirements to construction and protection princi-
ples are described in the IEC 60079-7 standard.
An enclosure must be constructed to withstand mechanical impact Ex e
and provide a specified degree of ingress protection (IP Rating). Figure 16. Increased safety enclosure
Two fundamental requirements of increased safety protection are
that the equipment shall be protected to IP54 minimum for gas /
vapor and IP6X for dust hazards.
This method of protection can be used in both Zone 1/Division 1
and Zone 2/Division 2 hazardous areas. Therefore, it is also often
preferred to flameproof protection method “Ex d” due to the need for
reduced levels of maintenance and inspection.
Another major consideration is that increased safety equipment is
often constructed from light-weight materials, which often leads to
lower cost.

4.4. Non-Sparking – “Ex n”
Non–sparking protection is regulated by the IEC 60079-15 European

standard. The non-sparking enclosure is permitted for use only in Zone
2/Division 2 hazardous areas. It is considered to be incendive so that
it does not generate arcs or sparks or dangerous temperatures in nor-
mal operation. Internal component temperatures must be controlled Ex n
and wiring connections must be selected with “non-sparking” in mind.
The concept has similarities with the “increased safety – Ex e” philoso- Figure 17: Non-sparking enclosure
phy but it is suitable only for Zone 2/Division 2 hazardous areas. The
equipment approved to “non-sparking” is not designed to withstand ex-
plosion, and will usually employ a light enclosure metallic construction
with a high ingress protection level.
There are several sub forms of the non-sparking protection concept:

• Non-sparking Ex nA –components of equipment are selected for non-
arcing or sparking.
• Enclosed break Ex nC – incentive components enclosed and sealed
to exclude gas or vapor from reaching ignition capable components.
• Restricted breathing Ex nR – relies upon the sealing and gasketing of
the electrical equipment to ensure that a flammable mixture is kept
Ex m
away from any hot surfaces and ignition capable components so Figure 18: Encapsulation enclosure
that it doesn’t enter the enclosure in sufficient quantity to reach the
specific low energy level (L.E.L.) documented.
4.5. Encapsulation – “Ex m”

Encapsulation (e.g. sand) of arcing and sparking components or
equipment in a way that ensures that there is no exposure to explosive
mixtures that may be present, and the surface temperature is con-
trolled under normal and fault conditions and prevents ignition from
occurring. The design considerations are stated in the IEC EN 60079-
18 standard.
4.6. Pressurized – “Ex p” Ex p

Pressurized or purged equipment, which is type “p,” relies on a com- Figure 19: Pressurized enclosure
bination of a positive static pressure applied inside of enclosure and a
continuous flow of air or inert gas to expel any explosive mixture that
may have entered inside. The system relies on purging schedules and
monitoring systems to ensure the reliability and effectiveness of the
overall protection. The IEC EN 60079-2 standard describes the require-
ments and design considerations.
4.7. Oil Immersion – “Ex o”

Permitted only in Zone 2/Division 2 areas where the likelihood of a
flammable atmosphere is remote. The type “o” equipment or enclo-
sures use the concept where the sparking components are inserted in
Ex o
oil and controlled venting is also a feature.
Figure 20: Oil immersion enclosure

5 Marking of Electrical Equipment
Electrical Equipment Marking
5.1. ATEX CE marking

Marking is mandatory and must be placed on equipment before it is assigned to be distributed in the market
or put into service. The intention is to facilitate the free movement of equipment within the European Union by
signifying that essential health and safety standards have been met. It is a declaration that the product was
produced in conformity with all applicable provisions and requirements of the Directive 94/9/EC and that the
product has been the subject of the appropriate conformity assessment procedures.
The ATEX 94/9/EC Directive specifies the minimum requirements for marking that have to be implemented.
Further information and requirements to marking of equipment for use in hazardous areas are given in the Eu-
ropean standards. The IEC EN 60079-0 standard defines the requirements on electrical equipment for use in
explosive atmospheres. For equipment intended for use in areas with combustible dusts, standard EN 61241-0
has to be applied.
Figure 21: Marking example of electrical equipment for Zone 1 / Division 1
To clearly identify the device, the type of identification and the serial number have to be stated as well as the
manufacturer’s name or trademark. Electrical equipment needs to be tested and approved by an appropriate
certified body, so the name of the notified body issuing the certificate and the certification number has to be
stated. The applicable use of the device is described through special coding. The following example refers to
equipment marking for gas atmospheres.
II 2G Ex ib IIC T4 Gb
Equipment protection level (Chapter 3.2.3)
Surface temperature class (Chapter 3.4)
Hazardous substance group (Chapter 3.2.1)
Type of ignition protection method (Chapter 5)
'Ex' indicates compliance with explosion proof standards
Equipment category and hazardous atmosphere - gas (Chapter 3.2)
Equipment group (Chapter 3.2)
Indication that this is an explosion-protected device
Figure 22: Typical electrical equipment marking (gas) according to ATEX 94/9/EC

For equipment certified for use in the hazardous areas with the dust atmosphere following marking is used:
Electrical Equipment Marking
II 2D Ex tD A21 IP66 T60°C

Temperatur class (Chapter 3.4)
Ingress protection rating; dust/water (IEC 60529)
Test method used to test for dust tightness (Zone 21 approved)
Explosion protection against dust
'Ex' indicates compliance with explosion proof standards
Equipment category and hazardous atmosphere - gas (Chapter 3.2)
Equipment group (Chapter 3.2)
Indication that this is an explosion-protected device
Figure 23: Typical electrical equipment marking (dust) according to ATEX 34/9/EC
Additionally, the following Markings can sometimes be seen:
Marking Description
II (2) The brackets show that the product must be installed in the safe area but it can be connected to
the equipment installed in the hazardous area
[Ex ib] The brackets indicate that the device must be installed in the safe area
nA Non-sparking equipment; does not generate a spark during normal operation
nL Energy limited, intrinsically safe during normal operation (note: since EN 60079-15:2010 became
effective, the 'nL' marking has been replaced with 'ic' marking)
Table 15: Additional markings for electrical equipment (ATEX 94/9/EC)

5.2. NEC marking
Essentially, the NEC markings contain similar sets of information as ATEX markings; however, it is important
to note the differences and ensure that equipment in use in any hazardous environment conforms to all ap-
propriate safety standards. The equipment classified for Division area are marked in accordance to the area
that it is classified.
IS Class Div. 1 Group T4 Ta

I, II, III A-F
Ambient temperature
Hazardous substance group (Chapter 3.3.1)
Hazardous area classification (Chapter 3.3)
Equipment class (Chaper 3.3)
Equipment approved by notified body
Figure 24: Example of electrical equipment marking according to NEC500
Alternative marking is used by classification of areas according to Zoning methodology. An example of the
equipment marking to NEC505 is shown in Figure 25. The equipment within the Zone method is marked in
accordance with the type of protection used similar to ATEX methodology. It is then the responsibility of the
user to apply the proper method of protection in each Zone.
IS Zone 1 AEx ib IIB T4 Ta

Class I
Ambient temperature
Hazardous substance group (Chapter 3.2)
Type of ignition protection method (Chapter 4)
Symbol of explosion protection
Hazardous area classification (Chapter 3.3)
Equipment class (Chapter 3.3)
Equipment approved by notified body
Figure 25. Example of electrical equipment marking according to NEC505

6 Electrical Equipment - Installation and Maintenance
Installation and Maintenance
6.1. Hazardous area inspections

When electrical equipment is installed in a hazardous environment, there are different inspection stages that must
occur to ensure equipment does not become the ignition source in the “Triangle of Fire.” The Triangle of Fire refers to
the three elements required for a fire to ignite: flammable substance ingition source and oxidizing agent (chapter 1).
The first stage of inspection happens prior to equipment being brought into service. An initial inspection is per-
formed to validate that equipment meets the requirements of the hazardous area. Those requirements are defined
by the customer in accordance with specifications defined by the equipment manufacturer.
Once hazardous-area equipment is installed, a periodic inspection schedule should be set to ensure the equip-
ment still meets the initial inspection requirements at a later time.
6.2. Types of inspection

According to IEC 60079-17 [ed4.0], there are five different inspection methods that ensure the continued reliability
of plant equipment used in a hazardous environment: initial, visual, close, detailed and continuous supervision.
Initial inspection
The initial inspection provides a thorough assessment that the selected type of protection and its installation are
appropriate. This inspection is validated using the control diagram produced by the equipment manufacturer. This
validation should be performed at installation, prior to equipment use.
Visual inspection (periodic)

The least invasive assessment of hazardous-area equipment is the visual inspection. This inspection is performed
while the equipment is energized and does not require the equipment to be isolated or any special tools. It evalu-
ates potential defects that are obvious by sight.
Close inspection (periodic)

Building upon the visual inspection, the close inspection is also performed while the equipment is energized.
However, the close inspection reveals defects that would not be apparent by sight. This inspection requires the
use of additional tools and, for example, identifies loose bolts. A close inspection is appropriate whenever regular
maintenance is performed.
Detailed inspection (periodic)

The detailed inspection is the most thorough inspection. It builds upon the visual and close inspections and pro-
vides a complete assessment inside and outside the equipment enclosure. It requires that equipment is isolated
from the hazardous area and identifies defects, such as degradation of sealing gaskets and/or compounds and
ensuring all electrical connections are tight and secure. A detailed inspection is appropriate whenever a repair is
performed or following a visual, close or detailed inspection in which a potential problem is identified.

Continuous inspection
Utilizing visual or close inspections, this inspection requires personnel who has experience in the specific in-
stallation and environment to frequently inspect, service, care for and maintain the electrical installation. The
use of continuous inspection does not remove the requirement for initial and periodic inspections.
6.3. Factors to determine periodic inspection intervals

Accurately determining an appropriate periodic inspection interval is a complex issue. The type of installation
application helps to determine the periodic inspection interval, along with manufacturer’s guidance and fac-
tors impacting equipment deterioration. There are two main types of installation applications hazardous-area
equipment falls under: fixed installations and moveable (portable) equipment.
Fixed installations
For intrinsically safe equipment installed in a fixed location, the maximum interval between periodic inspec-
tions should not exceed three years without seeking expert advice. Once an interval is determined, additional
periodic inspections should be performed to support or modify the proposed interval.
Moveable (portable) equipment

Moveable or portable intrinsically safe equipment is more prone to damage or misuse than fixed installations
and therefore the interval between periodic close inspections should be a maximum of every 12 months.
Enclosures that are frequently opened, such as battery housings, should have a detailed inspection at least
every six months. Additionally, all equipment should be visually inspected by a trained operator before use to
ensure that it is not obviously damaged.
Deterioration of equipment
When determining periodic inspection intervals, additional consideration should be taken for the environment
in which the equipment is used and potential equipment deterioration or degradation over time. Major factors
affecting equipment degradation include:
• Susceptibility to corrosion
• Exposure to chemicals or solvents
• Likelihood of accumulation of dust or dirt
• Likelihood of water ingress
• Exposure to excessive ambient temperatures
• Risk of mechanical damage
• Exposure to undue shock or vibrations

Manufacturer guidance
Installation and Maintenance
Guidance from the equipment manufacturer should also be taken into consideration when determining periodic
inspection intervals. Through rigorous testing, the original equipment manufacturer has to prove the product can
withstand the requirements of the specified regulatory bodies’ approvals by supplying certificates of conformity,
drawings and other supporting materials. This provides them with a unique and detailed understanding of equip-
ment capabilities.
Inspection type comparison

The table below compares the three main periodic inspection types.
External inspection Internal inspection Tools required

Visual inspection ✔
Close inspection ✔ ✔
Detailed inspection ✔ ✔ ✔
Table 16: Periodic inspection types


6.4. Intrinsically safe equipment inspection schedule
According to IEC 60079-17[ed4.0], Table 17 indicates the inspection table for intrinsically safe installations look-
ing at the three following categories: equipment, installation and environment.
A Equipment Detailed Close Visual

1 Circuit and/or equipment documentation is appropriate to the ✔ ✔ ✔
EPL/zone requirements of the location
2 Equipment installed is that specified in the documentation – ✔ ✔
fixed equipment only
3 Circuit and/or equipment category and group correct ✔ ✔
4 Equipment temperature class is correct ✔ ✔
5 Installation is clearly labeled ✔ ✔
6 Enclosure, glass parts and glass-to-metal sealing gaskets ✔ ✔
and/or compounds are satisfactory
7 There are no unauthorized modifications ✔
8 There are no visible unauthorized modifications ✔ ✔
9 Safety barrier units, relays and other energy limiting devices ✔ ✔ ✔
are of the approved type, installed in accordance with the
certification requirements and securely earthed where required
10 Electrical connections are tight ✔
11 Printed circuit boards are clean and undamaged ✔
B Installation Detailed Close Visual
1 Cables are installed in accordance with the documentation ✔
2 Cable screens are earthed in accordance with the ✔
documentation
3 There is no obvious damage to cables ✔ ✔ ✔
4 Sealing of ducts, pipes and/or conduits is satisfactory ✔ ✔ ✔
5 Point-to-point connections are all correct ✔
6 Earth continuity is satisfactory (e.g. connections are tight, ✔
conductors are of sufficient cross-section) for non-
galvanically isolated circuits
7 Earth connections maintain the integrity of the type of protection ✔
8 Intrinsically safe circuit earthing and insulation resistance is ✔
satisfactory
9 Separation is maintained between intrinsically safe and ✔
non-intrinsically safe circuits in common distribution boxes or
relay cubicles
10 As applicable, short-circuit protection of the power supply is in ✔
accordance with the documentation
11 Specific conditions of use (if applicable) are complied with ✔
12 Cables not in use are correctly terminated ✔
C Environment Detailed Close Visual
1 Equipment is adequately protected against corrosion, weather, ✔ ✔ ✔
vibration and other adverse factors
2 No undue external accumulation of dust and dirt ✔ ✔ ✔
Table 17: Inspection table for intrinsically safe installations

7 Weighing in Hazardous Areas
Weighing in Hazardous Areas
Weighing is one of the most basic and important process variables in a vast majority of manufacturing pro-
cesses. However, it can be one of the most challenging parameters to control.
Accurate and consistent filling, dosing and batching reduce variability in the end product, which ensures con-
sistently high quality. To achieve reliable quality and reproducible results requires efficient capture and com-
munication of weighing data to the existing plant network, which can be challenging due to hazardous-area
requirements.
To prevent any ignition and provide safe operation of electrical weighing systems in hazardous areas, one
possibility is limiting energy to safe levels. To achieve low energy and prevent ignition, the main components
of weighing systems, such as load cells, junction boxes and weighing terminals are designed for intrinsic
safety. Intrinsically safe technology prevents explosions by ensuring that the energy in intrinsically safe circuits
is well below the energy required to initiate an explosion.
Intrinsically safe electrical equipment and wiring is designed and certified mostly for use in Zone 1/Division 1
hazardous areas as long as they are approved for the location. Intrinsically safe circuits often combine ele-
ments with the various safety levels. Depending on functionality and the classification of the safety level, the
circuit elements can be applied either in hazardous or non-hazardous areas.
7.1. Basic system

In hazardous production areas, there are many processes which require simple standalone weighing applica-
tions. Filling tanks, drums or bags with hazardous powders or liquids is one example.
A simple weighing system usually consists of strain gauge (analog) or digital weighing platforms or load cells
controlled and monitored directly through a PC installed in a safe area. The weighing signal is interpreted by
the hazardous-area terminal and transferred to the safe area computer or printer. As all components of the
weighing system are intrinsically safe, the weighing system is powered by an intrinsically safe power supply.
Communicating the weighing signal from the Zone 1/21, Division 1 to the safe area requires energy-limiting
devices referred to as intrinsically safe barriers. These are barriers installed in the safe area that interface with
the communication device to prevent excess energy from a fault occurring on the safe side from crossing over
to the hazardous area.
Under normal operating conditions, intrinsically safe barriers have no arcing or heat-producing contacts, and
if specially marked, they can be installed in the Zone 2/22, Division 2. In fault conditions, the barriers limit
voltage and current to levels that are not sufficient to ignite the hazardous atmosphere.
These barriers consist of three components:

• The zener diode, which limits the voltage to a value referred to as an open circuit voltage (VOC)
• A resistor, which limits the current to a specific value known as a short circuit current (ISC)
• The fuse, which limits the maximum current that can flow through the diodes. When the current flows
through diode, the fuse will blow. This interrupts the circuit and prevents the diode from failing. As a result,
the excess voltage does not reach the hazardous area.

Communication to the safe area requires a safety analysis based on a comparison of intrinsically safe device
entity parameters with the hazardous-area approved safety barrier entity parameters.
Intrinsically safe weighing terminal Intrinsically safe barrier or communication

(Intrinsically safe apparatus) module (associated apparatus)
Open circuit voltage (Voc) ≤ Vmax
Short circuit current (Isc) ≤ Imax
Allowed capacitance (Ca) ≥ Ci
Allowed inductance ≥ Li
Table 18: Entity parameters of intrinsically safe equipment and associated equipment
This determines if the peripheral device is safe for connection to the intrinsically safe equipment. Entity param-
eters are usually found on the control drawing of the intrinsically safe device supplied by the manufacturer or
on the Examination Certificate (see Table 18). There are some differences in the abbreviations of US Class/
Division and Europe Zone classification. The US Class / Division system uses the abbreviation of entity pa-
rameters like VOC, ISC, and CA. In Europe, the safety parameters are referred to as VO, IO, CO, etc.
Figure 26 shows the example of a basic system with direct communication to a PC in a safe area. The intrinsi-
cally safe RS232 communication line is simply passing through the grounded intrinsically safe barrier before
connecting to the intrinsically safe weighing terminal installed in the hazardous area Zone 1/21, Division 1.
Benefits:
• Simple application through intrinsically Limitations:
safe RS232 interface • Short signal distance (15 - 20 m maximum)
• Cost efficiency • Safety barrier requires securely implemented
• Precise signal response earthing system
• Small barrier footprint
Weighing Terminal - IDNet PC connection

IDNet Interface
Power Supply
COM 1 - Intr. Safe RS232 Serial RS232 Zener barrier
Digital platform IDNet
Intr. safe RS232
Power supply
All apparatuses require equipotential bonding.

All earthing points to the same location.
Figure 26: Direct RS232 communication in the safe area

To ensure safe system set-up and function, terminal and safety-barrier entity parameters must be compared. Ta-
bles 19 and 20 show this comparison, reviewing both active and passive signals.
Zener barrier Weighing terminal

MTL7761Pac COM 1 RS232
Active Passive
Uo = 9 VDC ≤ Ui = ±10 VDC
Io = 26 mA ≤ Ii /mA = No limitation
Po = 58 mW ≤ Pi mW = No limitation
Co = 4.9 nF ≥ Ci /nF (Negligible) + Ccable / nF
Lo = 3.72µH ≥ Li/µH (Negligible)+Lcable / µH
Table 19: Entity parameters of zener barrier – active
Zener barrier Weighing terminal

MTL7761Pac COM 1 RS232
Passive Passive
Ui = 9 VDC ≥ Uo = ±5.36 VDC
Ii = 26 mA ≥ Io = ± 18.1 mA
Pi = 58 mW ≥ Po = 24.2 mW
Ci /nF (Negligible)+Ccable / nF ≤ Co = 4.9 nF
Li/µH (Negligible)+Lcable / µH ≤ Lo = 3.72µH
Table 20: Entity parameters of zener barrier – passive
Many different safety barriers are available. Take time to know the technical details and entity parameters of any
chosen safety barrier solution to ensure safety.
7.2 Advanced system

In the case of advanced data communication capabilities, such as communicating via Ethernet or programma-
ble logic controller (PLC), the amount of transferred data can be increased. This requires a more powerful and
sophisticated interface between the hazardous and safe area, as well as more powerful and sophisticated com-
munication modules themselves.
The intrinsically safe current loop interface performs best when large amounts of data must be communicated
from the hazardous to the safe area. Figure 27 shows an example of advanced system set-up. Safe area com-
munication is achieved by the intrinsically safe communication module, which has a functional principal that is
based on a current loop interface.
The current loop interface provides one or two full channels of bidirectional communication and is designed to
use a copper-wire cable. High speed transmitters and receivers are used to increase data throughput. When
combined with the communication module and its options, this permits remote operation in the safe area with
Ethernet and PLC interfaces at distances up to 300 meters (1,000 ft.) from the intrinsically safe weighing terminal.
Benefits: Limitations:
• Long signal distance (up to 300 meters maximum) • Bigger barrier footprint requirements
• Enhanced high-speed data communication • Additional wiring

The enhanced set-up allows large amounts of data to be gathered efficiently from the hazardous area Zone
1/21, Division 1 and integrated with standard PLC interfaces, such as EtherNet/IP, Profibus, DeviceNET, and
ModbusTCP. To ensure safe communication to the hazardous area, hazardous-area certified cable glands
must be used on all intrinsically safe connections. Standard communication to a safe area PLC and Ethernet
typically uses the standard, factory installed cable gland.
ACM500 - CL
Weighing Terminal - Analog Power Supply
Analog Interface COM 4 -CL
Power Supply COM 5 -CL
COM 1 - RS232 Slot 1

ETHERNET
COM 4 -CL
Analog platform
COM 2 - RS232
COM 5 -CL
COM 3 - RS232/422/485
RS232
Printer
RS232
Power supply Remote terminal

(Tare, Print, Zero, Clear)
PC connection

Figure 27: Current loop communication
7.3. Process control

Handling, filling, dosing, blending or batching of hazardous liquids or solids requires precise control. Small
process changes can have a big impact on end-product quality. Variations in proportions, speed, flow, turbu-
lence and many other factors must be carefully and consistently controlled to produce the desired end product
with a minimum of raw materials and energy. Process control through discrete internal Inputs/Outputs (I/Os)
keeps the weighing process running within specified limits and allows more precise target limits to be set to
maximize profitability and ensure quality and safety.
Remote I/O technology can be a cost-efficient and flexible solution for data control in processing plants. How-
ever, good management of this type of system is particularly critical for hazardous areas where explosion
protection measures for all system components are generally required

7.3.1 Active / active control
In the case of active/active control (Figure 28), both active inputs and active outputs are installed in the hazard-
ous area. Signal inputs are powered internally by the weighing terminal and are designed to be used with simple
switches housed within the hazardous area. Signal outputs are also powered by the weighing terminal and pro-
vide 12V switching at 50mA total. These outputs are intended for use with extremely low power, intrinsically safe
solenoids or piezo fluid control valves.
Intrinsically safe
ACM500 - CL
control valve
Up to 6 x active Weighing Terminal Power Supply
outputs / 12VDC
max. 50mA total Power Supply COM 4 -CL
Slot 1
COM 4 -CL
ETHERNET
COM 5 -CL
COM 2 - RS232
COM 3 - RS232/422/485
I/O
RS232
PC connection
Switch
Junction box Remote display
Power supply

Figure 28: Active / active control with internal discrete I/O module
Entity parameters of the I/O module must be compared to the output entity values of the intrinsically safe weigh-
ing terminal (see Table 21).
I/O module active Connect device passive

Uo = 5.88 DCV ≤ Ui / V
Io = 2 mA ≤ Ii /mA
Po = 2.94 mW ≤ Pi mW
Co = 100 nF ≥ Ci /nF +Ccable / nF
Lo = 100 µH ≥ Li/µH+Lcable / µH
Table 21: Entity parameters of the I/O module
In the safe area, communication with peripheral devices, such as PC, remote terminal, or printer is possible
through the intrinsically safe module with wide range of interfaces such as Ethernet or RS232/422/485.

7.3.2. Active / passive control
In the active input/passive output set-up (Figure 29), active input controls are installed in the hazardous area.
The passive outputs are usually high-voltage solenoids, which are not approved for hazardous-location use
and must therefore be considered for installation in the safe area. Passive inputs allow connection of an exter-
nal intrinsically safe voltage supply to power switches or other simple devices to trigger the input.
Both active inputs and passive outputs are powered by the intrinsically safe weighing terminal, which is in-
stalled in the hazardous area. The terminal, in turn, is powered through the external intrinsically safe power
supply, which meets hazardous-area requirements.
ACM500 - CL
Weighing Terminal Power Supply

ETHERNET
COM 4 -CL
COM 2 - RS232
COM 5 -CL
COM 3 - RS232/422/485
Simple switch
Up to 4 active inputs
I/O
Switching amplifier
Control valve
Up to 6 passive outputs to external
switching amplifiers
PLC
Junction box
Power supply
Figure 29: Active input / passive output valve control

I/O module - passive output Switch amplifier

Ui = 15 V ≤ Uo / V
Ii = 40 mA ≤ Io / mA
Pi = 150 mW ≤ Po mW
Ci / nF +Ccable = 10 nF ≥ Co / nF
Li/µH+Lcable =10 µH ≥ Lo / µH
Table 22: Entity parameters of the I/O module output
An isolated switch amplifier combines a safety barrier with higher-level voltage control. The entity parameters of
the switch amplifier must be compared to the entity parameters of the intrinsically safe weighing terminals (see
Table 22).
7.3.3. Passive input / passive output control

Passive inputs can be used when the input signal is coming from the safe area or some other type of active
device, such as a PLC. The protective switch amplifier provides controls passive outputs and high voltage sole-
noids or other controls in the safe area. The external switch amplifier receives a high voltage and converts it into
an intrinsically safe voltage to send to the weighing terminal in the hazardous area. Passive outputs remain iso-
lated while signaling to switch the higher AC or DC voltage through the switch amplifier.
The simple switch can be protected by the galvanically isolated type of barrier. The barrier provides complete iso-
lation and limits the high voltage coming from the switch, converting it to intrinsically safe voltage before sending
it back to the I/O module in the hazardous area (Figure 30).
The entity values of the safety barrier or the external power supply must be compared to the entity parameters of
the intrinsically safe weighing terminal passive inputs (see Table 23).
ACM500 - CL

ETHERNET
COM 4 -CL
COM 2 - RS232
COM 5 -CL
COM 3 - RS232/422/485
I/O
Switching amplifier
PLC
Control valve
Up to 6 passive outputs to external
switching amplifiers
Galvanically
isolated barrier Simple switch
Junction box
Power supply
Figure 30: Passsive input / passive output valve control

Intrinsically safe terminal passive
Galvanically isolated barrier
input parameters
Ui = 30 V ≤ Uo / V
Ii = 50 mA ≤ Io / mA
Ci / nF +Ccable = 10 nF ≤ Co /nF
Li/µH+Lcable =10 µH ≥ Lo / µH
Table 23: Entity parameters of the passive input
7.4. Fully integrated process control

To increase efficiency, reduce variability and ensure maximum safety, fully integrated process control is the
method of choice. For example, in multipurpose plants where several components are filled, mixed, blended
and dispensed at the same time, an internal I/O system supporting 12 inputs and 18 outputs can be the right
choice. To achieve the maximum number of I/Os, safe-area active remote modules can be used. These mod-
ules are not approved for installation in the hazardous area.
Active remote modules are capable of switching the high voltage to control the energy in the hazardous area
and require advanced intrinsically safe communication modules, which serve both as a safety barrier and
provide enhanced Ethernet communication. The current loop interface provides two-channel bidirectional
communications to the hazardous area. Weighing data can be stored on the PC through the Ethernet commu-
nication or the system can be connected to the PLC using Profibus (Figure 31).
ACM500 - CL
IDNet Interface COM 5 -CL

ETHERNET
COM 4 -CL
COM 2 - RS232
COM 5 -CL
COM 3 - RS232/422/485
Intrinsically safe
control valve
Up to 6 x active I/O
outputs / 12VDC
max. 50mA total
Ex Control valve Up to 3 x ARM 100 modules
Simple switch Maximum 12 inputs & 18 outputs
Simple switch
Up to 4 active PC connection
inputs
Zener barrier
Digital platform IDNet
Power supply

Figure 31: Fully integrated process control

Maintenance, Service & Warranty
7.5 Optional safe-area peripherial communications

Depending on weighing process requirements and the degree of automation required, different communication
possibilities allow efficient communication to the safe area.
When defining data transfer requirements to efficiently communicate weighing results to higher level manufactur-
ing execution systems (MES) or enterprise resource planning (ERP) systems, several points must be considered:
• What type of information will be communicated between the weighing terminal and automation system?
• What triggers initiate data transfer and how frequently will communication be made?
• What are the present data format requirements? Are those requirements flexible?
• What is the current communication medium? Are there other viable options?
• How might data format requirements or the communication medium evolve in the foreseeable future?
The key to data integration is having the correct connection to your wider control system. Whether it is a PLC,
MES or an ERP system, connection requirements for hardware and software differs. Options include fieldbus in-
terfaces, such as analog output, Profibus, DeviceNet or EthernNet/IP; and data interfaces such as Ethernet TCP/IP
or serial interface communication.
When purchasing a new weighing system, the data integration capabilities must match the data requirements of
the wider manufacturing system. METTLER TOLEDO offers two different possibilities of communication in the safe
area that can meet these system requirements.
The basic ACM 200 communication module approved for the safe area installation provides the connective link
between the weighing system installed in the certified hazardous area and the computer, printer or remote con-
trol terminal in the safe area. This module provides a flexible choice between different communication interfaces
such as RS232, RS422, RS485 and CL20mA.
Advanced weighing applications require enhanced control as well as enhanced safe area communication. The
communication module ACM500 plays an important role for such application types providing a number of op-
tional interfaces from RS232 to PLC data integration.
If PLC data integration is not required, PC-based serial or Ethernet TCP/IP data communication options become
viable.
Figure 32: Communication modules: ACM200 (left) and ACM500 (right)

8 Summary
Summary
Safety is crucial for businesses that operate in potentially explosive environments. Standards and regulations
play an important role in these hazardous manufacturing venues by specifying the framework of conditions
that guide both equipment manufacturers and operators to help ensure safety in manufacturing.
Many standards that are applied worldwide are based on other standards. While standards are similar
throughout the world, there is still no uniform global standard. Furthermore, symbols on the respective labels
differ. Therefore, products sold globally also must have various certifications for different explosion-risk envi-
ronments.
Many countries in Southeast Asia and Latin America have no local standards of their own and accept interna-
tional and national IECEx, ATEX and FM approvals. However, locations such as China, Korea, Japan and Rus-
sia have local certification requirements to which equipment must be adhered, although primary certification
schemes may be accepted for most purposes, depending on the nation.
Weighing is an important component of many manufacturing processes, and it requires special attention
when conducted in hazardous areas. Though weighing system components may be both intrinsically safe
and non-intrinsically safe depending on where and how they are used, it is crucial to ensure they have an ap-
propriate level of safety and provide required communication possibilities.
There are several options when it comes to ignition protection in hazardous environments. Installing intrinsi-
cally safe weighing equipment is the safest method. It safely facilitates activities in the hazardous area and is
low maintenance. When fire or explosive incidents occur, the units can be serviced without halting production,
and it eliminates heat and sparks in the production area.
METTLER TOLEDO focuses on development of intrinsically safe weighing systems. The intrinsically safe weigh-
ing solutions provide the benefits of modularity for a wide range of weighing platforms, weighing modules
and control terminals. It also offers flexibility with various communication interfaces, such as serial interfaces
and wide range of Fieldbuses.
Moreover, the weighing equipment is developed for use in hazardous areas and has obtained approvals on
the global level, including IECEx, ATEX, and FM, which are accepted in most countries.

9 List of Figures and Tables
List of Figures and Tables
List of Tables
Table 01: Flammable substances characteristics 07
Table 02: Comparison of ATEX, NEC/CEC and IECEx 16
Table 03: Equipment group and category classification according to ATEX 94/9/EC 19
Table 04: ATEX substance group classification 19
Table 05: Zone classification according to ATEX 1999/92/EC 20
Table 06: Definition of ATEX 94/9/EC equipment categories and IECEx equipment protection level 22
Table 07: Comparison ATEX 94/9/EC and ATEX 1999/92/EC 22
Table 08: Hazardous locations classification system according to NEC 500 – 505 23
Table 09: NEC 500 and NEC505 substance group classification 24
Table 10: Ignition temperature classes 25
Table 11: Temperature classes vs. substance group system 26
Table 12: Protection methods and related standards 27
Table 13: Intrinsically safe protection levels 30
Table 14: Terms and definitions for intrinsically safe equipment 30
Table 15: Additional markings for electrical equipment (ATEX 94/9/EC) 34
Table 16: Periodic inspection types 38
Table 17: Inspection table for intrinsically safe installations 39
Table 18: Entity parameters of intrinsically safe equipment and associated equipment 41
Table 19: Entity parameters of zener barrier – active 42
Table 20: Entity parameters of zener barrier – passive 42
Table 21: Entity parameters of the I/O module 44
Table 22: Entity parameters of the I/O module output 45
Table 23: Entity parameters of the passive input 47
List of Figures
Figure 01: Triangle of fire 06
Figure 02: Explosive limits diagram 08
Figure 03: Explosion protection concepts 10
Figure 04: Global map of guidelines and standards 11
Figure 05: Global view of hazardous standards and regulations 12
Figure 06: European Community standards and directives 13
Figure 07: USA standards and regulations 14
Figure 08: Definition of equipment groups and categories according to ATEX 94/9/EC, respectively NEC500 18
Figure 09: Zone classification according to IEC EN 60079-10 and ATEX 1999/9/EC, respectively NEC500 20
Figure 10: Duration and presence of hazards compared to risk (Zone) 21
Figure 11: Duration and presence of hazards compared to risk (Division) 23
Figure 12: Comparison NEC and ATEX /IECEx class and zone classification system 27
Figure 13: Intrinsically safe enclosure 29
Figure 14: Intrinsically safe circuit 29
Figure 15: Explosion proof enclosure 31
Figure 16: Increased safety enclosure 31
Figure 17: Non-sparking enclosure 32
Figure 18: Encapsulation enclosure 32
Figure 19: Pressurized enclosure 32
Figure 20: Oil Immersion enclosure 32
Figure 21: Marking example of electrical equipment for Zone 1 / Division 1 33
Figure 22: Typical electrical equipment marking (gas) according to ATEX 94/9/EC 33
Figure 23: Typical electrical equipment marking (dust) according to ATEX 34/9/EC 34
Figure 24: Example of the electrical equipment marking according to NEC500 35
Figure 25: Example of the electrical equipment marking according to NEC505 35
Figure 26: Direct RS232 communication in the safe area 41
Figure 27: Current loop communication 43
Figure 28: Active / active control with internal discrete I/O module 44
Figure 29: Active input / passive output valve control 45
Figure 30: Passsive input / passive output valve control 46
Figure 31: Fully integrated process control 47
Figure 32: Communication modules: ACM200 (left) and ACM500 (right) 48

10 References
References
• C22.1-12 - Canadian electrical code, part I (22nd edition): Safety standard for electrical installations
• DIN EN 50281-2-1: Electrical apparatus for use in the presence of combustible dust
• Directive 94/9/EC on equipment and protective systems intended for use in potentially explosive atmos-
pheres (ATEX); European Parliament and the Council
• Directive 1999/92/EC on minimum requirements for improving the safety and health protection of workers
potentially at risk from explosive atmosphere (ATEX); European Parliament and of the Council
• IEC 60079-0 Ed. 6.0 b:2011; Explosive atmospheres - Part 0: Equipment - General requirements
• IEC 60079-10-1 Ed. 1.0 b:2008; Explosive atmospheres - Part 10-1: Classification of areas - Explosive
gas atmospheres
• IEC 60079-10-2 Ed. 1.0 b:2009; Explosive atmospheres - Part 10-2: Classification of areas - Combustible
dust atmospheres
• IEC 60079-11 Ed. 6.0 b:2011; Explosive atmospheres - Part 11: Equipment protection by intrinsic safety "i"
• IEC 60079-17 Ed. 5.0 b:2013; Explosive atmospheres - Part 17: Electrical installations inspection and
maintenance
• IEC 60079-26 Ed. 2.0 b Cor.1:2009; Explosive atmospheres - Part 26: Equipment with equipment protec-
tion level (EPL) Ga
• National Electrical Code, Article 500, NFPA 70, 2011, Delmar: National Electric Code
• National Electrical Code, Article 505, NFPA 70, 2011, Delmar: National Electric Code
Additional METTLER TOLEDO Resources
• On-Demand Webinar 'Hazardous Area Standards and Regulations':

www.mt.com/ind-hazweb-standards
• On-Demand Webinar 'Hazardous Area – Advanced':
www.mt.com/ind-haz-advanced
• Hazardous Area Product Catalog:
www.mt.com/ind-hazcat
• White papers
www.mt.com/whitepapers
• Intrinsically Safe Solutions
• Safety Competence - Hazardous Area Standards and Regulations
• Weighing in Hazardous Areas – Safe – Easy - Flexible
• Proper Maintenance Scheduling: Intrinsically Safe Equipment

Download Free Catalog
Hazardous-Area Weighing Solutions
Harsh, potentially explosive environments require safety and compli-

ance. Easily select the right equipment for your hazardous area ap-
plication with our new catalog.
Equipment for safety and top performance

We provide the most extensive range of Ex products designed to
comply with global regulations and deliver the great weighing accu-
racy you expect from METTLER TOLEDO.
Learn more about solutions we can

offer you, including:
• Terminals for manual and
automatic weighing applications
• High-precision scales
• Bench and floor scales
• Weigh modules and load cells
• Vehicle scales
• Accessories
Download the free catalog now:

} www.mt.com/ind-hazcat
www.mt.com/ind-hazcat
For more information
Mettler-Toledo AG
CH-8606 Greifensee
Switzerland
Tel. +41 44 944 22 11
Fax +41 44 944 30 60
Subject to technical changes

© 10/2014 Mettler-Toledo AG
MarCom Industrial
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2 METTLER TOLEDO - Hazardous Area Guide ©2014 Mettler-Toledo AG

Chapter 1 Explosion Protection - Basics 06

Chapter 2 International Standards and Regulations 11

Chapter 3 Hazardous Area Classification 18

Chapter 4 Ignition Protection Methods 28

Chapter 5 Marking of Electrical Equipment 33

Chapter 6 Electrical Equipment - Installation and Maintenance 36

Chapter 7 Weighing in Hazardous Areas 40

Chapter 9 List of Tables and Figures 50

©2014 Mettler-Toledo AG METTLER TOLEDO - Hazardous Area Guide 3

1. Explosion Protection - Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. International Standards and Regulations . . . . . . . . . . . . . . . . . . . . . . . .

3. Hazardous Area Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Ignition Protection Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Marking of Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Electrical Equipment - Installation and Maintenance . . . . . . . . . . . . . . .

7. Weighing in Hazardous Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. List of Tables and Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 METTLER TOLEDO - Hazardous Area Guide ©2014 Mettler-Toledo AG

©2014 Mettler-Toledo AG METTLER TOLEDO - Hazardous Area Guide 5

1.1. Explosive atmosphere and explosion

Most manufacturing and processing industries generate po-

1. Flammable or explosive substance

1.1.1. Flammable or explosive substances

Flammable (explosive) substances can be divided in three groups:

6 METTLER TOLEDO - Hazardous Area Guide ©2014 Mettler-Toledo AG

100% Vol. Oxygen concentration 0% Vol.

Mixture is too lean to cause Mixture is too rich to

0% Vol. Concentration of flammable substance 100% Vol.

Figure 2: Explosive limits diagram

©2014 Mettler-Toledo AG METTLER TOLEDO - Hazardous Area Guide 7

8 METTLER TOLEDO - Hazardous Area Guide ©2014 Mettler-Toledo AG

1.2. Prevention of explosion

©2014 Mettler-Toledo AG METTLER TOLEDO - Hazardous Area Guide 9

Primary explosion protection is based on the concept of prevent-

In the absence of flammable substances, no ignitable mixture Ignition source

1.2.2. Secondary explosion protection

such as electromagnetic, ultrasonic etc.

Equipment designers are searching for different ways to elimi-

nate those sources. This can be done by:

• Using appropriate housing materials, such as stainless steel,

which prevents formation of sparks

• Using proper earthing and conducting materials

Figure 3: Explosion protection concepts

10 METTLER TOLEDO - Hazardous Area Guide ©2014 Mettler-Toledo AG

Country Canada USA USA Europa Russia China Japan Australia

Figure 4: Global map of guidelines and standards

©2014 Mettler-Toledo AG METTLER TOLEDO - Hazardous Area Guide 11

2.1. Global regulations for electrical equipment

ATEX CENELEC UL and FM NEC

2.2. European standards and directives

12 METTLER TOLEDO - Hazardous Area Guide ©2014 Mettler-Toledo AG

2.2.1. ATEX Directive

IEC IEC NFPA

ATEX CENELEC UL and FM NE

2.2.2. The ATEX product directive – 94/9/EC

Ultimately, it is the equipment manufacturer's

As such, the manufacturer must PTB KEMA

©2014 Mettler-Toledo AG METTLER TOLEDO - Hazardous Area Guide 13

2.3. USA and Canada regulations and standards

14 METTLER TOLEDO - Hazardous Area Guide ©2014 Mettler-Toledo AG

• Using appropriate housing materials, such as stainless steel,

• Using proper earthing and conducting materials