Cooper Crouse-Hinds - The World's Leading Manufacturer of Electrical Products for Commercial, Industrial, and Hazardous Environments

2004 Ex Digest

Nowhere else will you find a more comprehensive global guide to hazardous locations.
- Basics of Explosion Protection - Area Classification - Methods of Explosion Protection - Equipment Selection - Installation & Wiring Practices	- Testing and Approvals - Cold Weather Applications - Disconnect Switches - Lighting - Portable Power
The Cooper Crouse-Hinds Ex Digest is an invaluable design guide on classified areas highlighting the differences between Divisions and Zones.
When you want the most useful resources, go to the most reliable source…Cooper Crouse-Hinds.

TABLE OF CONTENTS Click on each chapter below to view its complete TABLE OF CONTENTS

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1. THE ELECTRICAL CODE EVOLVES

2. BASICS OF EXPLOSION PROTECTION

	OPEN CHAPTER 2
	2.1 North American Definitions
	2.2 The Hazard Triangle - The Oxygen Side
	- The Fuel Side
	- The Ignition Side
	2.3 Ignition Sources (Gases & Vapors) - Upper & Lower Flammable Limits
	- Flash Point of Flammable Materials
	- Auto-Ignition Temperature
	- Vapor Density
	2.4 Gas Grouping - North American versus IEC Practices
	2.5 Temperature Classification
	2.6 Ignition Sources - Minimum Explosive Concentration
	- Minimum Ignition Temperature
	- Dust Explosions

3. AREA CLASSIFICATION

	OPEN CHAPTER 3
	3.1 Comparison Between Divisions & Zones
	3.2 Present Day Hazardous Area Classifications and Product Mix
	3.3 Area Classification—Practical Approach
	3.4 Adequate Ventilation
	3.5 Who Classifies Hazardous Locations?
	3.6 Class I Hazardous Locations
	3.7 Definition of Divisions
	3.8 Definition of Zones - Zone 0
	- Zone 1
	- Zone 2
	3.9 Zone Classification Summary
	3.10 Examples of Hazardous Area Zone 3.10 Examples of Hazardous Area Zone Classifications

4. METHODS OF PROTECTION

	OPEN CHAPTER 4
	4.0 Principles of Explosionproof Protection
	4.1 Flameproof Type ‘d’ Protection Design Concepts - Flameproof Type ‘d’ Protection
	- Flameproof vs. Explosionproof—What is the Difference?
	- Flameproof Applications
	4.2 Increased Safety Type ‘e’ Protection Design Concepts - Increased Safety Type ‘e’ Protection
	- Enclosures
	- Terminals
	4.3 Intrinsic Safety Type ‘ia’ Protection Design Concepts - Intrinsic Safety Type ‘ia’ Protection
	- Ex-ia Limits the Energy
	- Ex-ia Applications
	4.4 Pressurized Type ‘p’ Protection Design Concepts - Pressurized Type ‘p’ Protection
	4.5 Non-Sparking Type ‘n’ Protection Design Concepts - Non-Sparking Type ‘n’ Protection
	- Ex-n Applications
	4.6 Powder Filled Type ‘q’ Protection Design Concepts - Powder Filled Type ‘q’ Protection
	- Ex-q Applications
	4.7 Oil Immersion Type ‘o’ Protection Design Concepts - Oil Immersion Type ‘o’ Protection
	4.8 Encapsulation Type ‘m’ Protection Design Concepts - Encapsulation Type ‘m’ Protection

5. TESTING & APPROVALS

	OPEN CHAPTER 5
	5.1 Hazardous Area Electrical Equipment Standards - National Standards & Codes of Practice
	5.2 Certification of Ex Protected Equipment - Approvals vs. Certifications
	- Test Authorities
	- Certificates of Conformity
	- Component Certificates
	- Certification of Ex Electrical Equipment
	5.3 NEMA vs IP Ratings - Conversion of NEMA Enclosure Type Numbers to IP Classification
	- Environmental Ratings Used For Light Fixtures - Marine Grade
	- Shell Deluge Test
	5.4 Approval Markings - North American Markings—CEC
	- North American Markings—NEC
	5.5 ATEX—The New European Approval Process - The CE Mark—New Markings, Certifications and Documentation
	- Zone 2 Standards
	- Are IEC Products Certified for Zone 2 Acceptable in North America?
	5.6 New ATEX Requirements Class II - Dusts & Zones 20, 21, 22 - ATEX Concept of Locations—Categories
	5.7 ATEX Approvals on OEM Equipment - ATEX Approvals for OEMs
	5.8 The IEC EX Scheme

6. SELECTION, INSTALLATION & WIRING OF Ex CERTIFIED ELECTRICAL EQUIPMENT

	OPEN CHAPTER 6
	6.1 Understanding the Difference in Zone vs Division Installation Methods
	6.2 Standards and Installation Practices
	6.3 Selection of Ex Protected Electrical Equipment
	6.4 Background of Wiring
	6.5 Typical Installation Conduit vs Cable - Rigid Conduit
	- Teck Cable
	- Armored Cable
	- Steel Wire Armored
	- Steel Wire Braided
	- Lead Sheath
	- Non-Armored Cable
	6.6 Termination Methods - Twist On Connectors
	- Terminal Boxes
	6.7 Terminating Armored Cable and Conduit in Non-metallic Enclosures - Zone Rated Hubs
	- Brass Bonding Plates
	6.8 Cable Seals
	6.9 When is Nickel Plating Required?
	6.10 Terminating Non-metallic EX-e Glands -Selection of Non-metallic Glands

7. INSTALLATION OF EXPLOSIONPROOF AND FLAMEPROOF ENCLOSURES

	OPEN CHAPTER 7
	7.1 Explosionproof vs Flameproof
	7.2 Flameproof Enclosures - Flamepaths and Joints IIB vs IIC
	7.3 Entries to Flameproof Enclosures - Indirect Cable Entry
	- Direct Cable Entry
	- Cable Glands
	- Mineral Insulated Metal Sheath Cables
	7.4 Weather-proofing of Flameproof Joints - Cold Temperature Applications
	7.5 Conduit Entry
	7.6 Conduit Seals
	7.7 Factory Sealed Devices
	7.8 Ground Continuity
	7.9 Checklist for the Installation of Flameproof Enclosures

8. INCREASED SAFETY TYPE ‘e’ PROTECTION DESIGN CONCEPTS

	OPEN CHAPTER 8
	8.1 Ex-e Enclosures
	8.2 Ex-e Terminals
	8.3 Lighting Circuits in Ex-e Enclosures
	8.4 New Increased Safety Wiring Practices
	8.5 Combination of Terminals & Wiring—Watch for Heat Dissipation
	8.6 Grounding (Earthling) of Ex-e Terminal Boxes
	8.7 Terminal Connection System - Terminating Spare Conductors
	8.8 Important Considerations of EX-e Terminals
	8.9 Increased Safety EX-e Motors

9. INTRINSIC SAFETY

	OPEN CHAPTER 9
	9.1 Introduction
	9.2 Determining Safe Energy Levels
	9.3 Intrinsically Safe Barriers - Grounded Zener Barrier
	- Isolation Barriers
	- Remote I/O Products
	9.4 Select the Proper Product for Your Intrinsically Safe Application
	9.5 Installation, Maintenance & Troubleshooting of Intrinsically Safe Circuits - Wiring
	- Barrier Installation
	- Grounding
	- Sealing
	- Maintenance
	- Troubleshooting
	- Barrier Replacement

10. DISTRIBUTION OF POWER—DISTRIBUTION PANELS

	OPEN CHAPTER 10
	10.1 Introduction - Panelboard Basics
	- 120 vs 240 vs 480 Volt Rated Panelboards
	- Heat Tracing and Ground Fault Indication
	10.2 Design - Explosion Protected Enclosures
	- Explosion Protected Breakers
	10.3 Application of Panelboards
	10.4 Selecting Panels

11. MOTOR DISCONNECTS AND SAFETY SWITCHES

	OPEN CHAPTER 11
	11.1 Introduction
	11.2 Explosion Protected Design
	11.3 Horsepower Ratings of Switches
	11.4 UL98 vs UL508
	11.5 Switch Lockouts
	11.6 Variable Frequency Drive Switches
	11.7 Explosion Protection and Environmental Ratings
	11.8 Installation - Entry Methods
	11.9 Selecting Motors for Hazardous Locations

12. PORTABLE POWER

	OPEN CHAPTER 12
	12.1 Applications - Special Considerations
	- Polarization
	12.2 Configurations - National Configurations
	- IEC309 - CEE17 Configurations
	- IEC309 Configurations
	12.3 Equipment for Hazardous Areas - Interlocked
	- Delayed Action
	12.4 IEC Plugs for Hazardous Areas
	12.5 Periodic Maintenance - Inspection Schedule
	- Strain Relief
	- Contacts
	- Additional Checks

13. HID AND FLUORESCENT LIGHTING CONCEPTS

	OPEN CHAPTER 13
	13.1 Markets
	13.2 High Intensity Discharge Lighting - Differences Between North American & European HID Luminaires
	- Temperature Ratings
	13.3 Forms of Explosion Protection
	13.4 Restricted Breathing - Maintenance for Fixtures With a Test Port
	13.5 Fluorescent Lighting - Zone 2 Fluorescent Luminaires

14. INSTALLATION RECOMMENDATIONS FOR COLD ENVIRONMENTS

	OPEN CHAPTER 14
	14.1 Hazardous Areas
	14.2 Water Resistant Construction
	14.3 Lubrications
	14.4 Wiring
	14.5 Lighting
	14.6 Temperature Cycling
	14.7 Area and Process Heating
	14.8 High Abuse Areas
	14.9 Static Electricity
	14.10 Ambient Operating Temperatures for Cooper Crouse-Hinds Products

15. EXAMPLES OF IEC HAZARDOUS AREA CLASSIFICATIONS

	OPEN CHAPTER 15
	15.1 Industrial Pump - Outdoors, Pumping Flammable Liquid
	15.2 Industrial Pump - Indoors, Pumping Flammable Liquid
	15.3 Pressure Relief Valve
	15.4 Process Mixing Vessel
	15.5 Oil / Water Gravity Separator
	15.6 Control Valve
	15.7 Hydrogen Compressor
	15.8 Flammable Liquid Storage Tank
	15.9 Tank Car Filling Station

APPENDICES

	APPENDICES
	I. Gases and Vapors - Hazardous Substances Used In Business and Industry
	II. Dusts - Hazardous Substances Used In Business and Industry
	III. Canadian Hazardous Locations Certification Documents
	IV. IEC Hazardous Locations Certification Documents
	V. Comparison of U.S., Canadian, IEC and European Markings Required for Zone Certifications
	VI. Operating Temperature Ranges for Cooper Crouse-Hinds Products
	VII. Restricted Breathing Advances Safe Lighting
	VII. Test Schedule for Electrical Equipment to be Installed in Areas Subject to Water Deluge Systems