Technology & Services

Explosion Protection in Zone 2 Hazardous Areas

Electrical Categor y 3G Apparatus
a report by

CEAG Apparatebau Hundsbach GmbH & Co. KG

Introduction

During recent years, the importance of Zone 2-type

process instrumentation and lighting equipment for
the chemical, petrochemical and pharmaceutical
industries has increased constantly.
This is primarily based on the hope that this will lead
to more cost-effective installations. This article
therefore concerns itself with the basic requirements
for this kind of apparatus for explosive atmospheres.
It is meant to give the user some practical advice on
mounting and operating Category 3G equipment in
Zone 2 hazardous areas. It touches on important
aspects but does not claim to give a comprehensive
picture of all the rules and regulations that are
relevant in this field. For more details, we would like
to refer you to the European Directives 94/9/EC
and 99/92/EC and the regulations of the user
country as well as the European Standard EN
6007915 and EN 50021, etc.

European Standard referred to in Directive 94/9/EC.

When harmonised standards are used, it is implied that
the directives are indeed satisfied.
Standards

Standard EN 50021 applies to non-sparking

equipment and apparatus containing parts or electrical
circuits that, if left unprotected, would be capable of
igniting explosive gases in Zone 2 through arcs, sparks
or hot surfaces. Their construction must ensure that a
fault that might lead to an ignition is most unlikely to
occur under normal operating conditions.
Zone 2 equipment is classed as explosion-protected
material and therefore normally offers better
protection than apparatus of good industrial quality,
for example by ensuring minimum IP protection for
enclosures, their mechanical stress resistance and their
reduced susceptibility to the build-up of electrostatic
charges. Any explosion-protected apparatus
approved for Zone 0 or Zone 1 may also be operated
in Zone 2.

Zone 2 Definition

Hazardous areas are divided into zones depending on

the likelihood and duration of the presence of a
hazardous gas atmosphere. European standard EN
6007910 classifies Zone 2 as an area in which
explosion hazards through flammable gases do not
exist during normal operating conditions. Should an
explosive atmosphere arise, this would only happen
very rarely and for a short period of time only. This
applies to well-ventilated open air installations in
which vessels containing flammable material would
only be opened under exceptional circumstances (see
Figure 1).
This indicates that Zone 2 is indeed a hazardous area,
albeit of diminished dangers as compared with Zone
1 hazardous areas.
The construction of electrical apparatus to be
mounted in Zone 2 is governed by European
Standards EN 50021, which specify protective
measures such as nA, nC, nR, nL and nP. The
European Standard EN 50021 is listed as a harmonised
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It is the aim of type n equipment and its

subdivisions to offer an economical alternative for
Category 3G equipment in Zone 2 to the superior
safety levels of Category 2G/1G apparatus.
However, it is still necessary to carry out and
document a safety check of interconnected
equipment in an electrical loop in Zone 2 in order to
ensure explosion protection.
Category 3G electrical apparatus is divided into four
groups (protection measures). In general, this
category of devices bases all the protective measures
on normal operating conditions, also taking care of
the effective surface temperature and the ignition
properties of sparks.
Fault conditions need not be taken into
consideration. In addition, it is permitted to generate
ignition conditions during maintenance and repair
work as these are not classed as normal operating
conditions. However, foreseeable events that may
arise from operating conditions must be taken care of.

Technology & Services

Figure 1: Sufficiently Ventilated Open Air Plant Zone 2

Methods of Protection

Parameters

Methods of protection for Zone 2 equipment to

DIN EN 50021 are dealt with in brief as follows.

There are limitations to the inner volume of these

devices depending on the type of apparatus. Also,
the maximum operating temperature must be 10K
below the permissible temperature for the
encapsulating material.

nA Non-sparking Apparatus
(Simple, Increased Safety)

The construction ensures reliably that no unpermissibly

high temperatures or arcs or sparks on inner or outer
parts can cause a surrounding gas atmosphere to ignite.

Furthermore, the application is limited to AC 690

V and 16 A for enclosed switch gear or AC 254V
and 16 A for non-incendive parts. Elastic gaskets
must maintain their properties during the lifetime of
the equipment.

Applications

Applications

Plugs and sockets, low-energy apparatus (control and

instrumentation), fuses, lamps, transformers, batteries
and electrical motors, etc.

Contact systems, sparking apparatus, switch gear

coils, solenoid valves, motors, electronic printed
circuit boards, etc.

nC Sparking Apparatus or
Equipment Featuring Hot Surfaces or
Non-sparking Components
(Simple Flame-proof Enclosure or
Simple Moulded Encapsulation)

nR Equipment in Vapour-proof
Enclosures

Principle of Protection

Principle of Protection

Equipment is enclosed or hermetically sealed or

encapsulated to ensure reliably that it will survive
possible high temperatures or arcs or sparks causing
an explosion inside the enclosure and will not lead
to subsequent ignition of the surrounding gas
atmosphere or will avoid ignition of the
surrounding gas atmosphere reliably through their
non-incendiveness.

Principle of Protection

The construction ensures reliably that the ingress of

hazardous gases and vapours is limited.
Parameters

The power dissipation inside the enclosure must not

increase the operating temperature by more than 10K.
Housings and hot surfaces therein must satisfy the
temperature class regardless of whether they contain
sparking or non-sparking equipment. It must be
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Explosion Protection in Zone 2 Hazardous Areas

Figure 2: Explosion-proof Lighting for Zone 2

possible to check the vapour proofing of the

enclosure after the installation has been completed.
Elastic gaskets must maintain their properties
during the lifetime of the equipment. Also, the
maximum operating temperature must be 10K
below the permissible temperature for the
encapsulating material.

Applications

Measuring, monitoring and communication

equipment and their installations, sensors and energy
limited actuators, etc.
nP Simple, Pressurised Apparatus
Principle of Protection

Vapour proofing is not suitable for installations that

have to be switched frequently as this would
indicate the likelihood that switching takes place
when an explosive atmosphere of gas or steam
surrounds the housing.

The construction ensures reliably that a hazardous

area inside the enclosure is avoided by generating an
overpressure compared with the surrounding
atmosphere.

Applications

Parameters

Lighting, switch gear, measuring, monitoring and

communication devices and their installations (see
Figure 2).

Optical indication upon loss of pressure, e.g. caused

by leakage. It is not necessary to switch off power
when opening the enclosure.

nL Energy Limited Apparatus and

Circuits (Simple, Intrinsic Safety)

Applications

Principle of Protection

Equipment and controllers that generate sparks and

arcs or hot surfaces during normal operation can be
operated safely in Zone 2 using this method.

Energy limited circuits and components ensure

reliably that neither a spark nor a thermal effect is
capable of igniting a flammable atmosphere.

Approvals

Parameters

Energy limiting components must be operated at

no more than two-thirds of their nominal values
during normal operation.
A safety factor of one regarding sparks is considered
to be sufficient.
Minimum requirements for housings feature IP54
ingress protection. Circuits must be designed for
voltages below AC 60V or DC 75V. These must
not be exceeded by more than 40% during
temporary faults.
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According to EC Directive 94/9/EC, Category 1G

or 2G electrical equipment (for Zone 0 and Zone 1)
must be issued with an EC-type examination
certificate by a nominated body. Mechanical
equipment only has to fulfil these requirements for
Category 1 apparatus.
Category 3 electrical apparatus as well as Category 2
and 3 mechanical apparatus has to be issued with a
manufacturers declaration. The manufacturer of
electrical equipment for use in Zone 2 or mechanical
apparatus for use in Zone 1 or 2 must issue an ECtype examination certificate according to Directive
94/9/EC, which must be signed by a responsible
person of that manufacturer.

Technology & Services

Figure 3: Remote IO for Zone 2

the Epsilon X sign

the CE-mark.

enclosed by the hexagon and

Devices must also be issued with operating

instructions for the safe installation, operation and
maintenance if applicable.
Quality Assurance

This must state that the underlying safety

requirements in 3 of Directive 94/9/EC are met. If
EN 50021 is fulfilled for electrical equipment, it
implies that it comforms to the EC regulations.
For mechanical equipment for use in Zone 1, the
manufacturer has to deposit the underlying
documents on which the declaration is based with a
nominated authority.
Obviously, a manufacturer of Zone 2 equipment is
free to apply to a nominated body of the EC for
approval of their product in accordance with EN
50021 to be issued with a statement of conformity.
We prefer the latter approach since this ensures that
a recognised authorised body checks that the
conditions for hazardous area apparatus are met in
full independently from the manufacturer. We have
chosen this route despite or perhaps because of our
more than 30 years experience in the field of
explosion protection.
As an example, CEAG have had the PTB in
Brunswick issue a statement of conformity for their
Zone 2 lighting and flood lights as well as the whole
of the Remote I/O product range for Zone 2
mounting. The equipment carries the mark: II 3
G EEx nA II T4.
This makes use of the same electronics as the
intrinsically safe approved circuits that are EEx ia
IIC certified (see Figure 3).

Manufacturers of Category 3 equipment must prove

to apply a quality system to ensure that the products
are manufactured in accordance with EC regulations.
Normally, these producers as well as those of
Category 1 and 2 equipment use DIN ISO 9001.
In addition, the quality system of manufacturers for
Category 1 and 2 equipment will also be monitored
by the approval body, for example PTB according to
the Directive 94/9/EC. So, manufacturers of
Category 1 and 2 devices carry a significant
responsibility.
Responsible Person

Large enterprises in the field of explosion protection

often name a responsible person who can approve
and certify equipment for use in Zone 2. The person
will be able to issue a manufacturers declaration of
conformity in accordance with EN 50021.
Furthermore, these responsible persons can verify the
safety integrity of the interconnection of one or
more associated pieces of apparatus with intrinsically
safe equipment, even for Zone 1. The permission is
linked to the manufacturer and will be granted based
on the long-standing experience in the field of
explosion protection.
Harsh Environmental Conditions

Regardless of the required measures taken to ensure

explosion protection for a particular zone or area,
you will have to observe the ambient conditions
when selecting suitable equipment for a particular
plant or section thereof.

Placing on the Market

Zone 2 equipment has to be supplied with type tags

and labels according to Directive 94/9/EC. The
labels have to carry the necessary information about
the manufacturer or the details of the manufacturers
representative who is based in the EU. It also has to
state the device type and serial number, the number
of the EC-type examination certificate and details
about the explosion protection measures and
maximum values if applicable. Furthermore, there
must be an indication of the temperature class and
the maximum permissible ambient temperature if
this differs from +40C. The devices must also carry

Viewing these ambient conditions, it may be prudent

to employ Zone 1-approved apparatus even in Zone
2 to ensure the uninterrupted operation under these
circumstances.
In Zone 2, you often meet with a harsh environment
i.e. electronic circuits exposed to a corrosive
atmosphere. This application lends itself, in
particular, to encapsulated devices. The fieldbus FB
Remote I/O system may be the right answer. FB
modules are a flame-proof yet hot-swap type of
device for use in Zone 1, offering intrinsically safe
electrical circuits or circuits of increased safety.
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Explosion Protection in Zone 2 Hazardous Areas

As the electronics and layouts of both LB modules
for Zone 2 and FB modules for Zone 1 are identical,
an economical mix of the two systems is possible.
The housings that harbour the LB or FB modules
according to the declaration of conformity or the
EC-type examination certificate may be opened
during operation.
Since the IP ingress protection is reduced to a lower
level during this maintenance operation (IP30), you
should make sure that water or rain cannot enter the
enclosure at this point.
In Zone 1, the maximum permissible overtemperature
depends on the ignition temperature of the required
temperature class. It must not be exceeded even under
fault conditions. In contrast, Zone 2-certified
equipment must satisfy these requirements for normal
operation within the manufactures specifications only.
Temperature Proofing

Modules fitted on backplanes that are housed in

enclosures intended for use in Zone 2 are subject to
a temperature-proofing test in a similar way as
intrinsically safe devices are for hazardous area
mounting. It has to be shown that none of the
surfaces produce a temperature higher than the
maximum permissible ignition temperature of the
surrounding explosive atmosphere. In Zone 2, this
applies to normal operating conditions at the
maximum permissible ambient temperature.
Differences Between Zone 1 and
Zone 2

CEAG imposes the same demands on electrical

apparatus for Zone 1 or Zone 2 mounting during

development and production by set internal factory

standards. This concerns the safety of electrical
circuits, the choice of safety-related components and
assembly in housings and their material. There is also
a 100% factory test for all Zone 2 material. Where
possible, Zone 2 cost reductions are realised.
The company regulations are based on the
standards for the applicable protection methods for
electrical equipment for use in Zone 1 hazardous
areas. LB and FB Remote IO modules only differ
in the type of housing that suits the demands of
Zone 1 or Zone 2.
Summary

The article presented here points out the demands

on explosion-protected apparatus for use in Zone 2
hazardous areas. It is shown that this Category 3
equipment usually has to meet the same
requirements as regards intrinsically safe circuits as
equipment connected to Zone 1 hazardous areas.
The demands on intrinsic safety do not depend on
the mounting position but on the installation of the
intrinsically safe field loops. IS circuits in Zone 2
employ the same safety values as those in Zone 1,
with the difference that normal operation is the
basis of the design and not a possible fault
condition. Foreseeable events that may derive
from modes of operation must, however, be taken
into consideration.
This leads to the conclusion that Zone 2 designs may
offer a certain economical advantage. On the other
hand, safety aspects should not be neglected when
deciding on the area classification. A small
commercial advantage in the purchase of material
should not increase the operational risk and with it
the dangers to staff and plant property values.

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