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HAC Guide
HAC Guide
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This technical guide outlines the design and use of equipment protected against the ignition of hazardous atmospheres formed from gases, vapours or dusts. The information given applies specifically to Chalmit Lighting products and can also be used as a general guide. The guide refers to equipment and methods complying with safety practices being used throughout the world. This material is included both for completeness and because Chalmit operates throughout the world supplying all lighting requirements. Chalmit hazardous area products are designed and manufactured in accordance with the best engineering practices and to well established construction standards for explosion protected equipment. The equipment must be selected, installed, maintained and disposed of in accordance with any regulation or legislation appropriate to its use. Reference must be made to the data sheets and the certification applying to each individual product. The guide also refers to construction standards and application codes. The correct application of protected equipment is a specialist subject and these notes must be treated as being only informative. In addition to the Chalmit technical information users must themselves study the relevant codes of practice and construction standards. Installation operation and maintenance manuals (IOM) are enclosed with each product and are available on request. These contain information essential to the safe use of the equipment and must be read and understood by installers and users before putting equipment into service. Much of the information is also available on the Chalmit web site. Usually this will be for the latest version of a particular range. If detailed information on superseded product is needed Chalmit should be contacted directly.
Rationalisation
In order to eliminate this potentially long term anomaly at international level and to introduce the concept of a declared level of safety, IEC agreed to introduce Equipment Protection Levels [EPL's]. These EPL's are Ga, Gb and Gc for gas and Da, Db and Dc for dust. Ma and Mb also exist for mining. These are an alternative and additional specification for equipment made in accordance with the standards. The key point is that the definitions of product performance are in effect identical to the ATEX Category definitions. In future, rationalisation may see the EPL's incorporated into ATEX. The basic technical requirements for ATEX and IEC via the IEC Ex scheme (see the section on the IEX Ex scheme) will therefore be identical as EPL's are introduced right across the standards series. The ATEX marking is different from IEC and must be shown in addition to the IEC marking.
Sub-Division
A further effect of the introduction of EPL's is to give a definition to the emergence of sub-divisions in some of the protection concepts. The sub-division of 'intrinsic safety' into ia and ib has existed for many years. Now ma, mb also exist, further sub-divisions mc and ic will be introduced as well. Ex p is currently sub-divided into px, py and pz but will be rationalised. Sub-divisions of other concepts may be developed in due course and some existing requirements in the Ex n standard may be re-located.
As stated, where possible these IEC 61241 standards are being incorporated into the IEC 60079 series. In Europe these standards are becoming Euro Norms (EN's) and supersede the EN 50281 series. These new editions of the IEC standards for gas and dust have been prepared with the full participation of the USA. Products currently being produced may have marking and catalogue information in the EN 50000 series or EN 50281 series.
Euro Norms
Because of the movement towards IEC, references to EN's are not used in this introduction except where there is no current Euro-norme in the IEC series, in which case the EN numbering in the EN 50014 etc. series will be given in brackets.
International, Regional and National Standards Ongoing Changes Methods of Explosion Protection for Electrical Equipment in Explosive Gas Atmospheres General Requirements IEC 60079-0 Protection against the Ignition of Atmospheres containing Dusts Classification of Hazardous Areas and the use of Protected Equipment The EU ATEX Directives Protection Codes for Chalmit Products Examination Certificates IEC & ATEX Marking of an ATEX Product and the CE Mark Surface Temperature Rating and Gas Grouping Surface Temperature for Ignition Gas Grouping Protection against the Ignition of Explosive Atmospheres formed from Combustible Dust The IEC Ex Scheme International Standards Ingress Protection Resistance to Mechanical Damage Compliance with General Product Standards Operational Temperatures - Tamb 'X' suffix on Certificate Delayed Opening Cabling and Cable Glands
4 6 6 7 8 8 9 9 9 10 10 10 11 11
Lamps and Control Gear Lamp Standardisation Control Gear and Electrical Supplies Emergency Lighting Applications Glossary TABLES Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Methods of Explosion Protection Hazardous Areas Classification Selection of Protected Apparatus in Hazardous Areas according to EN 60079-14 EPL, ATEX Catagory, Design Requirements and Expected Application Classification of Maximum Surface Temperatures for Electrical Equipment IEC 60079-0 Gas Grouping for Electrical Equipment IEC 60079-0 Comparison of Practice A and Practice B for Dust Protected Enclosures Comparison of Surface Temperature Classification IEC and NEC Comparison of Representative Gases in IEC and NEC Gas Groups
16 18 18 18 19 19 6 8 8 9 10 11 12 13 13 14 14 15 17
12 12 14 14 15 15 15 15 16 Table 9
Table 10 Definition of Ingress Protection Table 11 Impact Energy Requirements for IEC 60079-0 Group II Equipment Table 12 Impact Energy Requirements IK Code Table 13 Summary of Lamp Characteristics and their Application
Type Of Protection
Ex e Increased Safety Ex nA Non Sparking tD (for dust hazards) Ex i intrinsic Safety Ex op Optical Radiation Ex nL Energy Limitation Ex Ex Ex Ex m Encapsulation p Pressurisation o Oil immersion nR Restricted Breathing
means of ignition
Designed to prevent any ignition from spreading outside of the apparatus Table 1
Ex s Special Protection
This method, being by definition special, has no specific rules. In effect it is any method which can be shown to have the required degree of safety in use. Much early equipment having Ex s protection was designed with encapsulation and this has now been incorporated into IEC 60079-18 [Ex m]. Ex s is a coding referenced in IEC 60079-0. The use of EPL and ATEX Category directly is an alternative for s marking.
Note: the definitions are for areas containing gas mist or vapour mixtures with air. The dust Zones have been added for ease of understanding and the definitions are effectively the same.
The deployment of protected apparatus in hazardous areas classified to EN 60079-10 is summarised according to EN 60079-14 in table 3.
Zone Zone 0 Type of Protection Assigned to Equipment Ex ia Ex ma and types of protection suitable for Zone 0 as constructed to IEC 60079-26 Any type of protection suitable for Zone 0 and Ex d, Ex ib, Ex py, Ex e, Ex q and Ex mb (Also see notes on Ex s protection) Any type of protection suitable for Zone 0 or 1 and Ex n, Ex mc, Ex pz and Ex o (Also see notes on Ex s protection) tD A20, tD B20, iaD and maD Any type of protection suitable for Zone 20 and tD A21, tD B21, ibD, mbD and pD Any type of protection suitable for Zone 20 or 21 and tD A22 IP 6X Table 3 Selection of Protected Equipment in Hazardous Areas Generally According to IEC 60079-14 and IEC 61241-14
Zone 1
Zone 2
Zone 20 Zone 21
Zone 22
The suffix A and B for the dust protection methods refer to the two practices A and B for the assessment of temperature with and without dust layers.
Examination Certificates
An EC type examination by a notified body is mandatory for Category 1 and 2 electrical equipment but not for Category 3. Chalmit Lighting have chosen to obtain a certificate of compliance from a third party for Category 3 equipment in order to ensure customer confidence and continue the long standing practice that Chalmit has used for Ex n equipment. The designation EC can not be used for certification of Category 3 equipment. In the data the term type examination rather than EC type examination is used for Category 3 equipment.
IEC & ATEX The relationship between IEC Equipment Protection Levels, ATEX Catagories amd applications is shown below in table 4.
IEC EPL ATEX Category Degree of Safety Design Requirement (condensed) Two independent means of protection or safe with two independent faults Safe with frequently occurring disturbances or with a normal operating fault Safe in normal operation Expected Zone of use
Ga Da Gb Db Gc Dc
10
T1 T2 T3 T4 T5 T6
Table 5
For dust protection using the enclosure methods, the surface temperature is limited to a given value in C, the T grouping prefix is not used.
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Gas Grouping
The gas and vapour mixtures are classified as shown in Table 6. The possible number of chemical compounds is very extensive and the list shown is only representative. The equipment sub-groupings, A, B and C are only applicable to the design and marking of flameproof, intrinsically safe, energy limited and non incendive equipment.
Group
I IIA IIB IIC
Representative Gases
All Underground Coal Mining. Firedamp (methane) Industrial methane, propane, petrol and the majority of industrial Ethylene, coke oven gas and other industrial gases Hydrogen, acetylene, carbon disulphide
Table 6
Protection against the Ignition of Explosive Atmospheres formed from Combustible Dust
In this catalogue are products for use with ignitable dusts. Explosives dusts i.e. those not requiring the presence of air to ignite are outside the scope of ignitable dust protection. The 5th edition of IEC 60079-0 Equipment - General requirements introduces Group III for explosive dust atmospheres and this group is sub-divided into, IIIA Combustible flyings, IIIB Non-conductive dust, IIIC Conductive dust. The detail requirements for the subgroups differ. With respect to the formation of an explosive atmosphere, the nature of dust is very different to that of gas or vapour. Dust, unlike gas does not disperse, it remains until cleared away by manual means or ventilation and can form layers. Layers of dust can ignite at much lower temperatures than clouds. This is because layers can insulate and increase the temperature and also because layers of some dust are prone to spontaneous combustion. The ignition of layers results in burning which can subsequently translate into an explosion. Layers have the potential to be disturbed and form clouds. Ignition data for dusts is given for clouds and layers. Typically, dust in a cloud form is harder to ignite than gas either by a hot surface or a spark. The maximum allowable surface temperature for equipment present in dust clouds is de-rated from the actual surface temperature of ignition of the dust. The allowable surface temperature for layers is subject to further de-rating where layers exceed 5mm thick and extra heavy layers require special laboratory investigation by the specifier or user. When installing floodlights, care must be taken to ensure that the face of the glass is positioned at such an angle that dust cannot settle. Ignitable atmospheres caused by dust may also be prevented from arising by ventilation, containment and by good housekeeping.
Area Classification
The area classification for dust is similar to that for gas, namely, Zone 20, Zone 21 and Zone 22, depending on the likelihood of a hazardous dust atmosphere being present (refer to table 2). As a generality, the zones are smaller than those for gas. Equipment may be marked as suitable for both gas and dust hazards. If the equipment carries marking for both dust and gas this does not mean both at the same time. Where an explosive gas atmosphere and a combustible dust atmosphere are or may be present at the same time, the simultaneous presence of both shall be considered and may require additional protective measures. The potential for ignition must be investigated by a qualified person.
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Protection Methods
The enclosure method, where dust is effectively excluded and the external surface temperature defined, is generally used for lighting. In the product data this is referred to as dust protected enclosure. This is now standardised as tD with sub-division into Practice A and Practice B. The Ex prefix symbol is not used for dust. The products in this catalogue using the dust protected enclosure are currently to EN 50281-1-1. The tD standard is incorporated into IEC 61421-1 and will be applied to all newly certified products. Sub divisions of Ex m; maD and mbD, Ex i; iaD and ibD also Ex p; pD have been introduced. The dust ignition protection method for products in this catalogue is by surface temperature limitation and enclosure to IP6X or IP5X as appropriate. IP6X is required for ATEX Category 1 and 2 and for conducting dusts in any Category. Ingress of a conducting dust can cause incendive insulation failure. IP5X is a minimum for Category 3. The surface temperature is limited to a given value in C. The table below outlines the difference between practices A and B Practice A Performance based Maximum surface temperature is determined with 5 mm layer of dust and installation rules require 75K margin between the surface temperature and ignition temperature of a particular dust. A method of achieving the required dust ingress protection by the use of resilient seals on joints and rubbing seals on rotating or moving shafts or spindles and determining dust ingress according to IEC 60529 - IP code. Table 7 Practice B Performance based and prescriptive Maximum surface temperature is determined with 12.5 mm layer of dust and installation rules require 25K margin between the surface temperature and ignition temperature of a particular dust. A method of achieving the required dust ingress protection by specified widths and clearances between joint faces and, in the case of shafts and spindles, specified lengths and diametrical clearances and determining dust ingress by a heat cycling test.
Reference is also made in this catalogue to products for use in NEC Class II and Class III locations. NEC dust protected products are to UL 844. The construction and testing is different to that specified in the Euro-norme but is very similar to the alternative Practice B given in the IEC standard.
International Standards
Two distinct groups of equipment standards used world-wide are the IEC/EN (Euronorme) series of standards and those used in the USA and areas influenced by US practice. A large proportion of work on hazardous area and equipment standards is now being carried out at IEC level and almost all EN's are identical with IEC. Many countries which have their own national standards have adopted the IEC standards in their entirety or incorporated material from them. The practice in the US has developed differently. The US engineering practice, legal requirements, regulations and the use of approval organisations such as UL, FM and ISA mean that, whilst the safety principles are much the same as in the rest of the world, the detail is significantly different. The US code of practice is the National Electrical Code (NEC) and the 'standard' exclusively used, until recently, for luminaires is ANSI/UL844. This standard integrates the designation of the hazardous area in which equipment is designed to be used and the protection method. For lighting purposes the types of protection are a flameproof type and a non-sparking type. These are used in Class 1 Division 1, and Class 1 Division 2 areas which are broadly equivalent to Zone 1 and Zone 2 respectively. Dust and fibre hazards are Classes II and III. The only basic technical difference between these and the equivalent IEC/EN standards is that the ANSI/UL844 'nonsparking' technique, known as 'enclosed and gasketed', does not use the restricted breathing method. This is one factor which accounts for the generally higher surface temperature ratings of ANSI/UL844 listed equipment and the practical need for a greater number of temperature sub-divisions. Another factor is that the ANSI standard specifies higher test pressures for flameproof equipment. In the case of HID luminaires this results in the lampglass being smaller and the surface temperature inevitably hotter. The construction and testing of dust protected enclosures is different to EN but is currently partially incorporated as an additional alternative in the IEC standards. In both codes the gases and compounds are classified by surface temperature of ignition and grouped into ignition groups for the dimensioning of flameproof joints and for intrinsic safety. The classification and grouping are broadly similar to IEC but differ in detail. The classification and protection cannot be mixed and must be used as complementary pairs. A general comparison between IEC and NEC practice for gas hazard protection is shown in Tables 8 and 9. The US standards are also influenced by the use of conduit wiring systems which, in contrast to cable, form a flameproof distribution method for Class 1 Division 1 and a damage and ingress protected distribution method for Division 2.
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Canadian Approvals
The Canadian practice has been a hybrid of US and European. The mining industry in Canada was much influenced by Europe which led to the use of European methods elsewhere. Through the joint accreditation system with the US (NRTL) there is a degree of overlap but the detail of this can not be addressed properly in this introduction. Canada has now adopted the zone system for new construction. Chalmit Lighting is part of the Hubbell Electrical Products division of Hubbell Inc, as such Chamlit can supply the products of sister company Killark providing a complete product portfolio to meet US and Canadian standards and codes. The combined range is comprehensive encompassing the vast majority of lighting products needed to satisfy applications in hazardous areas throughout the world.
Maximum Temperature C 450 300 280 260 230 210 200 180 160 160 135 120 100 85
Table 8
Surface Temperature Classification EN 50014 T1 T2 280C (T2) 260C (T2) 230C (T2) 215C (T2) T3 180C (T3) 165C (T3) 160C (T3) T4 120C (T4) T5 T6 ANSI/UL844 T1 T2 T2A T2B T2C T2D T3 T3A T3B T3C T4 T4A T5 T6
Representative Gas
Acetylene Carbon disulphide Hydrogen Ethylene oxide Hydrogen sulphide Ethylene Acrylo-nitrile Industrial methane Propane Ethyl acetate Table 9
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Ingress Protection
The surface temperature classification and gas grouping are the primary safety considerations. A major secondary parameter is protection against the ingress of solid bodies and liquids. In some cases the degree of ingress protection (IP) forms part of the standard requirement of the explosion protection method. Where equipment is used in dirty or wet conditions, high resistance to ingress contributes to the reliability of explosion protection in that electrical faults within the equipment are often the result of water ingress. For Chalmit products, the appropriate standard is IEC 60529. The definitions of the IP code are summarised in Table 9. It will be noted that many Chalmit luminaires have both IP66 and IP67 ratings. This is because the IP66 test can be more severe than IP67 for some constructions. The US has a system using the ANSI/NEMA 250 code which is similar but also contains tests for corrosion resistance.
Protection against ingress of large solid foreign bodies Protection against ingress of medium sized solid foreign bodies Protection against ingress of small solid foreign bodies greater in diameter than 2.5mm Protection against ingress of small solid foreign bodies greater in diameter than 1mm Protection against the ingress of dust in an amount sufficient to interfere with satisfactory operation of the enclosed equipment Complete protection against ingress of dust
1
Protection against drops of water
Protection against drops of liquid falling at any angle up to 15 from vertical Protection against rain falling at any angle up to 60 from the vertical Protection against splashing. Liquid splashed from any direction shall have no harmful effect Protection against water projected by nozzle from any direction
Protection against temporary immersion in water Protection against indefinite immersion in water. Tests to be agreed between supplier and customer.
Table 10
Enclosures and Guards Light transmitting parts without guard Light transmitting parts with guard when tested without guard Table 11
7 4 2
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IK Code
In addition to the index of protection against the ingress of foreign bodies and liquids, a third figure is sometimes quoted. This relates to the minimum levels of resistance to mechanical damage as measured by test methods producing an impact energy measured in Joules or Newton metres. It is often referred to as the IK code, the levels of protection for this index are detailed in Table 12 below. The test method is not the same as in the IEC standards.
IK Code
Impact energy (Joule)
IK00
a
IK01
0.14
IK02
0.2
IK03
0.35
IK04
0.5
IK05
0.7
IK06
1
IK07
2
IK08
5
IK09
10
IK10
20
Table 12
Delayed Opening
In those cases where internal temperatures are greater than the T rating or where energy is stored in electrical components, a delay before opening is marked on the equipment. This will give a minimum time limit to be observed following the interruption of electrical power. This allows for cooling and discharge of energy. It applies most practically to Ex d equipment. For Category 3 equipment, opening times are not usually given as it is inferred that an explosive atmosphere is unlikely to occur during maintenance operations.
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Lamp Type
Compact Fluorescent
Metal Halide
Mercury Vapour
Lamp Power range W Output range Lumens Physical size Temperature of lamp
70 to 1 kW 6000/13000**
70 to 2kW 5000/20000
Efficiency lumens per circuit watt Instant light Lumen depreciation Colour rendering Ra Economical life max (hrs) Ability to be focussed for floodlighting Emergency operation
up to 90
Up to 85
Up to 125
Up to 90
Up to 70
Yes Negligible V Good 95/100 1000 Some (tubular linear) Very easy (but inefficient) Poor Ex e Ex d Ex nR -50 to 60 T6 to T2
Easy
Easy
No
No
No
Vibration resistance Most common Ex protection methods T amb range C Common T ratings
Medium Ex nA Ex e
Medium Ex n Ex d
Good Ex d Ex nR
Good Ex d Ex nR
Good Ex d Ex nR
-20 to 55 T6 to T4
-20 to 55 T6 to T4
-50 to 60 T4 to T2
-30 to 55 T4 to T2
-20 to 55 T4 to T2
Table 13 * ** ***
Most fluorescent lamps have an economical life of 15000 hrs but some higher specification lamps are available which can run economically for up to 40000 hours. Equal to or less than 36000 hours when twin arc lamps are used. (See note below) HPS lamps are available which have two arc tubes in parallel inside the same envelope and are commonly known as twin arc lamps. They give 15% light output immediately after a brief supply interruption which extinguishes the lamp. They also give a longer service life.
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Lamp Standardisation
Most IEC type lamps are now standardised in form and cap dimensions even when, as newly developed lamps, they are not included in a standard. The US type lamps are generally somewhat different and are designed for use with US control gear. Some US fluorescent lamps are superficially identical to IEC lamps but may not run reliably on IEC control gear and vice versa. In addition, some US HPS lamps are identical in operating characteristics with IEC lamps but others have different operating characteristics. US and IEC lamp-cap sizes are often different. US metal halide lamps usually have quite different operating characteristics to European lamps and there are many varieties. Most must be operated on US control gear and sometimes a specific make of control gear if warranties are to be valid. Great care must be taken with the use of all metal halide lamps and details of their application will be found in the instruction manuals. Most products for IEC applications in this catalogue are designed to use metal halide lamps compatible with HPS (SON) ballasts. Lamps will also run satisfactorily provided they are compatible with both HPS and MBFU ballast impedances. In all cases check control gear for compatibility. If in doubt with metal halide lamps please contact your local Chalmit representative. Care must also be taken with the specification of compact fluorescent lamps, particularly whether they need to have a starting switch in the lamp. Most of the luminaires in the catalogue use 4-pin compact fluorescent lamps without internal starter switches. HPS/SON lamps with internal ignitors must not be used in Ex n or Ex N equipment. All Chalmit HID luminaires are suitable for use with twin arc HPS/SON lamps. Please consult Chalmit or your local representative if there are any uncertainties concerning lamps.
Emergency Lighting
Some luminaires for emergency lighting are contained in the catalogue. Where remote battery supplies are available these can supply tungsten or tungsten-halogen lamps of appropriate rating from dc supplies. Luminaires such as Protecta III, Acclaim, Curie Elite and Stirling II with electronic ballasts, can power fluorescent lamps from dc supplies. Most of the remaining range can be run at mains ac voltage from a UPS but the characteristics of the UPS must be compatible with those of the luminaire. For details of operation where full information is not included in the catalogue refer to Chalmit. The Protecta III, Acclaim, Curie Elite and Stirling II luminaires are also available with integral, self contained nickel-cadmium batteries to provide illumination on ac mains failure. The output is a given percentage of the full luminaire output depending on the lamp size chosen and the duration required.
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Applications
The Chalmit range of lighting products uses a wide range of lamps, each of which is suited to its particular application. The use of high intensity discharge lamps in floodlighting and high bay applications reduces the number of luminaires required with a consequential reduction in the amount of installation and maintenance time as well as cost. The Chalmit range also includes a number of luminaires for single point or local illumination and those using fluorescent lamps provide instant illumination of good light quality using low cost sources. The HID sources allow a compact luminaire construction that will reliably attain a high degree of ingress protection. Many fluorescent sources and the smaller HID sources can be housed in luminaires having plastic enclosures and these have additional applications in certain corrosive environments. The wide range of products and lamps ensures that Chalmit can supply the correct luminaire for the application. To assist you in developing a lighting design that will provide the optimum performance from Chalmit products for your specific applications, Chalmit have developed a user friendly lighting design package called CHALMLITE. This software programme is available free of charge and includes unique internal & external quantity estimators to provide a quick indication of the luminaire quantities required. Chalmit also offer a lighting design service to assist in the development of complex lighting designs tailored to meet exact project requirements.
Glossary
ANSI ATEX American National Standards Institute
Abr. Directive 94/9/EC Equipment and protective systems intended for use in potentially explosive atmospheres British Approvals Service for Electrical Equipment in Explosive Atmospheres. This was a government organisation that is now closed
Instrument Society of America Intertek Testing Services (formerly part of ERA) Netherlands Testing Laboratory National Electrical Manufacturers Association (US) Nationally Recognised Testing Laboratories (US) SIRA Certification Service (UK) Safety of Life at Sea (convention) Surface Temperature (Max)
BASEEFA
British Standards Institution Civil Aviation Authority (UK) Committee European de Normalisation
LAMP TYPES
EU FM IEC IP
TH QL LED