staubEX_e_04_10_04.qxd 21.10.

2004 12:49 Uhr Seite 33

the basics of
dust-explosion protection
staubEX_e_04_10_04.qxd 21.10.2004 12:47 Uhr Seite 2

Powders or dust like substances are processed or are byproducts of the production process in

many industries.

Whether the dust is useful (e.g. for the production of plastics, pigments or pharmaceuticals)

or waste, a large majority of dustlike substances pose the danger of fire or possibly even

explosions. Eighty percent of all industrial dusts are combustible, and even a dust layer of 1 mm

in a closed room is sufficient to result an explosion when the dust is swirled up and ignited.

These facts, combined with the fact that those affected are not sufficiently aware of the danger

(in contrast to the hazard of gas explosions) underlines the importance of preventing dust

explosions. This brochure is intended to help you analyse the risk of a dust explosion in your

facilities and to take the suitable technical and organisational steps to minimise this risk.

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 3

contents
1 Dust as a Risk Factor 4

2 Definitions and Characteristics 6

3 Legal Basis and Standards 10

44 Dust Explosion Protection Measures 12

55 Classification of Dust Explosion Hazardous Areas into Zones 14

66 Dust Types of Protection 16

77 Equipment Selection 22

88 Installation and Maintenance 28

9 Product Overview 30

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 4

dust-explosion protection
1 dust as a risk factor
4

1. Dust as a Risk Factor cess continues, and under some conditions

chain reactions such as these sweep through entire
As with flammable liquids and the explosive buildings or facilities, destroying them.
gas/air mixtures that result from them, certain
conditions must be fulfilled to ignite a mixture of As is the case with gases, there are various
dust and air by an effective ignition source ignition sources for dusts, such as sparks from
and thus trigger an explosion. No explosion can electrical or mechanical processes, arcs,
occur if one of the following is not present: open flames, electrostatic discharges, electro-
combustible dust, air, ignition source. magnetic waves and others.

Dust explosions have a different process of Figure 2 shows the results of statistical studies in
propagation than gas explosions and can in some North America, which examined the distribution
cases be much more devastating. If a gas/air of the ignition sources that caused dust explosions.
mixture is ignited, the force of the resulting ex- It shows that mechanically produced sparks
plosion causes the gas cloud to dissipate were responsible in almost one third of the cases.
rapidly and thus dilutes the gas/air mixture to a Add to that the 13 % of explosions caused by open
concentration lower than that necessary for further fire and welding, and it becomes obvious that
combustion. Thus, if no further gas is added, the many people are not aware of the danger of dust
explosion is over after several milliseconds. explosions. Figure 3 shows that a wide variety
of industries are affected, including branches of the
Figure 1: Explosion Risk Triangle
food and wood processing industries, paper and
plastics materials production, pharmaceuticals
production and others.

The data given above are confirmed by German

property insurers, who state that on average
there is one dust explosion per day in the Federal
Republic of Germany. Approximately one fourth
of these are caused by dust from food products or
animal feed.

With combustible dusts it is different. If, for

example, a draft of air swirls up a layer of dust in
a small area, the dust, along with oxygen, forms
a combustible dust/air mixture. If this mixture is
ignited by an ignition source, an explosion is
caused. The force of the resulting explosion swirls
up more dust, which is in turn ignited. This pro-

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 5

Figure 2: Ignition Sources of Dust Explosions

Figure 3: Types of Dusts Involved in Dust Explosions

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 6

dust-explosion protection
2 definitions and characteristics
6

2. Definitions and Characteristics In Table 2, the important characteristics determining

the explosion process of dust are listed. It is
What does the word dust really mean? necessary to assess your technical procedures in
The European Standard EN 50281-1-1 defines it view of potential ignition sources, volume of
like this: explosive dust atmosphere, operating temperature,
Dust consists of small solid particles in the etc. Subsequently, the potential for a dust explosion
atmosphere which settle due to their own weight, under the current conditions must be evaluated.
but which remain suspended in air for a time (this
includes dust and grit, as defined in ISO 4225). The most important terms in dust explosion pro-
tection are listed in Table 1 along with their
definitions. In Table 3, the characteristics of some
materials from the various product groups are
given. These technical safety characteristics have
been determined under standard conditions in
the laboratory. As a rule, conditions are in practice
less likely to lead to an explosion, so that the
figures are less alarming.

Be aware that a general term, such as flour dust,

can lead to false assessments. Wheat flour
has different technical safety characteristics than
rye flour, for example.

Table 1: Definitions in Dust Explosion Protection

Term Definition Remarks

Explosive Dust Mixture with air, under atmospheric conditions, of flammable The condition is that the process
Atmosphere substances in form of dust or fibers in which, after ignition, ends only after one reactant has
combustion spreads throughout the unconsumed mixture been entirely consumed.
(IEV 426-02-4).

Atmospheric Range of pressure between 0.8 and 1.1 bar

Conditions Temperature range between -20°C and + 60°C

Hazardous Explosive atmosphere in hazardous amount. The presence A thickness of a dust layer less
Explosive of a hazardous explosive atmosphere must be assumed if than 1 mm on the floor of a normal
Atmosphere ignition causes an exothermal reaction that endangers people, room is sufficient to cause a
domestic animals and property. hazardous explosive atmosphere.

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 7

Table 2: Explosion Characteristics

Characteristic Definition/Description Remarks

Size of particle Dust particles larger than 400 µm are not explosive. Depending on friction, the transportation and processing of
Dust particles are explosive when they measure less coarse dust result in the formation of fine dust.
than 400 µm and up to 20 µm

Explosion limits As with gases, dust is explosive within certain These characteristics vary widely throughout the entire range.
concentration limits: Extreme dusts can form an explosive mixture in concentrations of
lower explosion limit: approx. 20…60 g/m 3 air less than 15 g/m 3.
upper explosion limit: approx. 2…6 kg/m 3 air

Maximum explo- In enclosed containers of simple design, combustible dust In exceptional cases, such as with light metal dusts, explosive
sion pressure can reach an explosive pressure between 6 and 10 bar. pressure of up to 20 bar may develop.

KSt -value This is a classifying value expressing the shattering power This figure is the basis for calculating pressure relief areas.
of the combustion. Nummerically, it is equal to the value for
the maximum rate of explosion pressure rise during explosion
of a dust/air mixture in a 1 m 3 vessel.

Moisture The moisture of a dust is a significant factor with regard to its

ignitions and explosive behaviour. Although no exact limits ex-
ist, it is known that a higher moisture content requires a higher
ignition energy and impedes the formation of dust swirls.

Minimum igni- Lowest engery which is sufficient to effect ignition of Not every spark is capable of causing ignition. The decisive factor is
tion energy Emin the most easily ignitable explosive dust atmosphere under whether sufficient energy is introduced into the dust/air mixture to
speciefied test conditons ( EN 13237). initiate a self-substaining combustion of the entire mixture.
A modified Hartmann tube (Figure 5) is used to determine the minimum
ignition energy.

Ignition The lowest temperature of a hot inner wall of a furnace The shape of the vessel in which the ignition temperature is deter-
temperature of at which ignition occurs in a dust cloud in air contained mined has proved to be especially critical. It may be assumed that
a dust cloud Tic therein (EN 50281-2-1). ignition on differently shaped surfaces is, in practice, only possible
at much higher temperatures. In the case of dust from food products
and animal feed, this figure is between 410 and 500 degrees C,
depending on type.

Ignition The lowest temperature of a hot surface on which a This temperature describes the ignition behaviour of thin dust layers.
temperature of ignition occurs in a dust layer of specified thickness If the layer is thicker, or if the ignition source is completely inundated
a dust layer Til on a hot surface (EN 50281-2-1). by dust, the thermal insulation provided by the dust layer increases,
resulting in quite different, sometimes significantly lower temperatures,
which could trigger an exothermal reaction. Experiments have shown
that the ignition temperature decreases nearly linearly with an in-
crease in the layer thickness. The ignition temperature of a dust layer
is sometimes considerably lower than the ignition temperature of a
mixture of the same dust in air. The maximum permissible surface
temperature for electrical equipment may be higher, depending on the
dust’s thermal conductivitiy. Unnoticed glowing spots can exist un-
noticed for long periods in thick layers of dust and can, if the dust is
swirled up, become effective ignition sources.

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 8

dust-explosion protection
2 definitions and characteristics
8

Thus it is impossible to provide generally valid

characteristics for a particular kind of dust. There
are wide variations for identical dusts. Depending
on conditions, limit values often cannot be
determined exactly; nor then, can the risk of ex-
Table 3: Examples of Explosion Characteristics for Dusts
plosion. The minimum ignition energy can also
Substance Tic [°C] Til [°C] ØEmin [mJ] min [mJ]
vary to a large extent. In Table 3, the limit values
Wood ≥ 410 ≥ 200 ≥ 100 6 for several products are listed; that is, values
that border on the hazardous. In rare cases, the
Brown Coal ≥ 380 ≥ 225 – 5
dust/air mixture in question can also be ignited at
Coal ≥ 500 ≥ 240 ≥ 1000 13 considerably lower energies.

PVC ≥ 530 ≥ 340 ≥5 <1

Note that it is not possible to directly infer the
Aluminium ≥ 560 ≥ 270 ≥5 <1 minimum ignition temperature from the minimum
ignition energy, and vice versa.
Sulphur ≥ 240 ≥ 250 10 5

Table 2 includes detailed commentary on the

Lycopodium ≥ 410 – – –
characteristics for dusts.

Functional Description of a Modified

Hartmann Tube (Figure 5):
Figure 4: Determining a Dust’s Minimum Ignition Energy Not every spark is capable of ignition. The deciding
factor is whether the energy added to the mixture
is sufficient to initiate self-sustaining combustion
of the entire mixture. The modified Hartmann
tube is used as a qualitative test apparatus for the
minimum ignition energy. At the base of the tube
is an atomising cone which is employed to swirl a
defined quantity of the dust being investigated.
A compressed air blast of 7 bar swirls the dust in
the glass cylinder and the resulting mixture is then
ignited by a spark created between two electrodes.

A test is considered to be positive if the indication

instrument shows a deflection of the hinged
cover or, if a dust fire occurs (even if the hinged
cover is not moved).

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 9

Figure 5: Modified Hartmann Tube

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 10

dust-explosion protection
3 legal basis and standards
10

3. Legal Basis and Standards

In the most important industrial countries,

regulations and standards covering explosion
protection in areas exposed to dust hazard were
established early on. In the USA, standards
have existed since 1929, in Germany since 1976.

However, it was a comparatively long time before

the first international regulations at IEC level
Table 4: Dust Explosion Protection Standards appeared – 1993. Work on these commenced in
IEC EN
the mid-70´s, but the protective techniques used
in the different countries were so different that it
General requirements 61241-0 prEN 61241-0
was very difficult to establish common standards.
Type of protection “tD” 61241-1 50281-1-1 The IEC 61241:1993 series of standards was still
(61241-1-1) in future based on the two zone concept.
EN 61241-1

Before the new European directives for explosion

Selection and installation 61241-14 50281-1-2
(61241-1-2) in future protection (94/9/EC and 1999/92/EC) came into
EN 61241-14 force, explosion protection regulations in Europe
existed at the national level, based on the tow
Inspection and maintenance 61241-17 prEN 61241-17
zone concept.
Testing methods:
> Min. ignition temperature 61241-20-1 50281-2-1 In Germany the two zones were defined: Zone 10
(61241-2-1) and Zone 11, in Great Britan: Zone Z and Zone Y.
> Electrical resistivity 61241-20-2 61241-2-2 In Germany a special certification of design was
of a dust layer (61241-2-2) (50281-2-2) not required.
> Min. ignition energy 61241-20-3 50281-2-3
(61241-2-3) in future at CEN Although the special risk posed by dust explosions
> Lower explosion limit 61241-2-4 50281-2-4 has long been known, due to devastating
in future at CEN accidents in coal mines, the problem received
widespread attention in Germany only after
Classification of areas 61241-10 50281-3
61241-3
the flour dust explosion that completely destroyed
the Rolands Mill in Bremen in 1978.
Protection by pressurization 61241-2
“pD” (61241-4)

Protection by intrinsic safety 61241-11

“iD”

Protection by encapsulation 61241-18

“mD”

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 11

11

After this, in Germany a certificate of conformity Table 5: Comparison of “Old” IEC 61241 Standards and “New” Suggestion
for electrical equipment to be used in Zone 10
Number of Proposed Subject Planned
became a legal requirement, based on the VDE Current Standard New Number Date
standard. VDE 0170/0171, Part 13 developed by
following the action of IEC. Based on this standard, IEC 61241-1-1 IEC 61241-0 General requirements 2003

BVS (German Testlaboratory and Certification Body)

IEC 61241-1 Protection by enclosures “tD” 2003
and now EXAM have been certifying electronic
devices for use in Zone 10 since 1980, in IEC 61241-1-2 IEC 61241-14 Selection & installation 2003
co-operation with legal authorities and the PTB.
IEC 61241-2-1 IEC 61241-20-1 Test methods 2005

Directive 94/9/EC provided a new regulation IEC 61241-2-2 IEC 61241-20-2 Test methods 2005
for explosion protection in Europe. This directive
formulates the requirements to be fulfilled by IEC 61241-2-3 IEC 61241-20-3 Test methods 2005

manufacturers of electrical and no electrical IEC 61241-3 IEC 61241-10 Classification of areas 2003
equipment. The Explosion Protection Regulation of
December 1996 (Explosionsschutzverordnung) IEC 61241-4 IEC 61241-2 Protection by pressurization “pD” 2005
transfers this directive into German law. In Annex I,
IEC 61241-5 IEC 61241-11 Protection by intrinsic safety “iD” 2002
Directive 94/9/EC mentions, in the course of an
explanation of Equipment Group 2, only the danger – IEC 61241-18 Protection by encapsulation “mD” 2004
presented by an explosive atmosphere consisting
– IEC 61241-17 Inspection & maintenance –
of a dust/air mixture, which does not seem to in-
clude dust deposits. The special risk presented by – IEC 61241-19 Repair & overhaul –
these dust deposits as a source of release is only
taken into account in the zone classification
insofar as other circumstances, such as a swirling
up of the dust by air currents, could cause an 99/92/EC. As part of the consolidation of
explosive atmosphere. standards dealing with dust and gas, the goal at
the IEC level is to adapt the numbering of the
The questions of proper use are addressed by dust standards to the IEC 60079 standard series
Directive 1999/92/EC. The current treatment of (Table 5). This plan is laudable, because it
dust explosion protection in Directive 1999/92/EC would create analogous standards for gas and
is not very comprehensive and is limited to dust explosion protection.
a simple definition of zones and a reference to
deposits of combustible dust.

CENELEC, the European Committee for Electro-

technical Standardization, has developed
Standards EN 50281-1-1 and EN 50281-1-2 in
parrallel with IEC 61241 and based on it. These
standards make use of the 3-zone concept
as set out in European Directives 94/9/EC and

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 12

dust-explosion protection
4 dust explosion protection measures
12

4. Dust Explosion Protection Measures 4.2 Preventive Explosion Protection by Avoiding

Effective Ignition Sources
4.1 Preventive (Primary) Explosion Protection
by Avoiding an Explosive Atmosphere This measure prevents the hazardous explosive
atmosphere from being ignited. This can be
The complexity of the processes that can lead to achieved by:
a dust explosion means that it is extremely > Analysing potential ignition sources
difficult to assess the actual risks in dealing with > Determining the necessary extent of protective
explosive dust/air mixtures. This makes explosion measures
prevention measures especially important. > Using suitable equipment
These are generally considered to mean avoiding
or limiting the amount of a hazardous explosive For this reason, measures against a possible
atmosphere. One possibility is to reduce the ignition of a present explosive atmosphere are
concentration of the combustible substance to used. A precondition is that the workflow process
values below the “lower explosion limit” (see in question be assessed in adequate detail for
Table 2), such as by mixing it with non-combustible any possible ignition sources.
products. Another option is to prevent the
release of combustible substances or at least to The nature of the protective measures used and
limit it. Both of these measures can be effectively the level of safety required depend on the
supported by thorough and regular housekeeping hazardous zone in question. The probability of the
and by implementing suitable construction existence of an explosive dust atmosphere and
measures (see p. 15). If release cannot be avoided, the zone classification of hazardous areas derived
the surrounding air with its oxygen can be from it are important factors for deciding what
replaced as a potential reactant by a non- protective measures are necessary (see Section 5).
combustible gas such as nitrogen (inertisation).

However, high operational costs mean that

this method is limited to a small number of special
applications. If these measures cannot be
provided at a justfiable cost, there are other effec-
tive options of explosion protection available.

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 13

13

4.3 Constructional Explosion Protection this ejection process from the relief apertures
associated with the explosion pressure relief
Constructional explosion protection is a method of also contains burnt and unburnt combustible
avoiding the hazardous effects of explosions substances. It must always be checked whether
and/or of limiting the effects of an explosion to a the consequences of the explosion in the loca-
safe level by the use of: tion in question can be controlled.

> Explosion-resistant design limits an > Explosion suppression

explosion to the inside of pressure-resistant This process is generally used in vessels and
vessels or pressure-shockresistant vessels – production equipment for which an explosion
which, however, also means that connected pressure exceeding the explosion pressure
equipment such as tubes/pipes and decoupling resistance of the system in question is predicted.
measures must meet the same conditions. The explosion is suppressed in its initial
Explosion-pressure resistant vessels or stages, before a hazardous rise in pressure can
apparatus are those that can withstand many take place. To accomplish this, an extinguishing
times the expected explosion pressure without agent is used in the protected area within
being permanently deformed. fractions of a second of the explosion being
Explosion-pressure shockresistant vessels detected. For the suppression of an explosion
or apparatus are constructed so that they can (use of extinguishing agent) it is mandatory that
withstand the expected explosion pressure the explosion be detected promptly. In the
without breaking; however, permanent defor- case of explosions that begin slowly, the initial
mations may be a result. In this case, then, the pressure rise is not sufficient for its timely
robustness of the material may be brought identification. Additional measures such
closer to its limits. as optical flame detectors or supplementary
pressure detectors may be necessary.
> Explosion relief (defined pressure relief by
means of bursting discs, venting panels or > Explosion barriers (prevention of explosion
explosion doors, etc.) This measure is intended propagation, explosion decoupling).
to prevent the build-up of excessively high Isolation as an explosion protection measure
explosion pressure in the interior of vessels by allows the explosion to reach full force, but
the timely release through defined openings. prevents it from propagation into other, unpro-
This measure addresses only the effects of the tected parts of the system. This is accomplished
explosion, and can be implemented without by mechanical barriers which immediately
additional control mechanisms. As soon as the block connecting routes, or by a chemical ex-
static response ejection process from the tinguishing barrier.
protected apparatus into the surrounding area
begins. Apart from the flame and shock wave,

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 14

dust-explosion protection
5 zone classification
14

5. Classification of Dust Explosion Hazardous

Areas into Zones

Table 6: Zone Definitions

The classification into zones has proved its
effectiveness in gas atmospheres for years. The
Zone 20 A place in which an explosive atmosphere in the form of a cloud of com-
definition of zones agreed on throughout Europe in
bustible dust in air is present continuously, or for long periods or frequently.
NOTE: In general these conditions, when they occur, arise inside containers, accordance with Directive 99/92/EC applies only
pipes and vessels etc. to swirled-up dust. Accumulations and deposits of
combustible dust must be taken into consideration
Zone 21 A place in which an explosive atmosphere in the form of a cloud of combustible
dust in air is likely to occur in normal operation occasionally.
as well, like all other factors that could lead to
NOTE: This zone can include, among others, areas in the immediate vincinity the creation of an explosive atmosphere.
of e.g. powder filling and emptying points and areas where dust layers occur
and are likely in normal operation to give rise to an explosive concentration of
Dust deposits are seen merely as a “source of
combustible dust in a mixture with air.
release” for an explosive atmosphere.
Zone 22 A place in which explosive atmosphere in the form of a cloud of combustible
dust in air is not likely to occur in normal operation but, if it does, will Among other sources, EN 50281-3 (Classification
persist for a short period only.
of areas where combustible dusts are or may be
NOTE: This zone can include, among others, areas in the vincinity of
equipment, protective systems, and components containing dust, from which present) can provide help with the classification.
dust can escape from leaks and from dust deposits (e.g. milling rooms, in
which dust escapes from the mills and then settles). In Table 6 and Table 7, zone classification and zone
definitions are once again given, as well as the
connection between the zones and the equipment
categories of Directive 94/9/EC.

Table 7: Zone Concept and Impacts of Directives 94 / 9 / EC and 1999 /92 / EC

Presence No Effective Ignition Equip. Category Certification

of Hazardous Sources Present in Accordance Required
Explosive Atmo- with 94/9/EC for Electrical
sphere D (Dust) Equipment

Zone 20 Continuously, Normal operations Category 1D yes

long-term or and rare equipment
frequently malfunction and on
the occurence of two
independent faults

Zone 21 Occasionally Normal operations Category 2D yes

and frequently
occuring equipment
malfunctions

Zone 22 Rare and short Normal operations Category 3D no

period (manufacture's
declaration)

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 15

15

Classification According to Housekeeping Table 8: Housekeeping and Explosion Hazard

of Working Place Level of Thickness of Duration of Presence Fire or
Housekeeping Dust Layer of a Dust Layer Explosion Risk
High cleanliness of working area is very important
good zero or not present none
in dust explosion protection, as in contrast negligible
to gases a series of releases that are individually
under the explosion limit can lead to a hazardous fair not negligible shorter than the none
length of 1 shift
accumulation of dust (see also 4.1, Preventive
(Primary) Explosion Protection). poor not negligible longer than the fire hazard and
length of 1 shift Zone 22 if clouds
The Directive 99/92/EC and specially the Guide of are created

this Directive, paragraph 3.1.4.1 refer to obligatory

cleanliness standards.

In the new version of the Standard “Classification Figure 6: Example of the Classification into Dust Explosion Hazardous Areas
of areas where combustible dusts are or may be According to IEC 61241-10

present” according to IEC 61241-10 and

Zone 20 Inside the hopper of
EN 50281-3, the degree of housekeeping is
quantified and included in the classification of
22 a bag emptying station

Zone 21 Immediate surround-

the areas (Table 8). ings (radius of 1 m)
21 around the manhole
20 Zone 22 Area outside Zone 21
due to accumulatios
of dust

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 16

dust-explosion protection
6 dust types of protection
16

6. Types of Dust Explosion Protection > Dust-protected enclosure

An enclosure which the ingress of dust is not
The goal of explosion protection is to prevent totally prevented, but does not enter to interfere
excessive temperatures and energies in the form with the safe sufficient quantities to operation
of sparks, arcs and so forth in an equipment. of the equipment. Dust shall not accumulate in a
position within the enclosure where it is liable
Currently four types of dust ignition protection to cause an ignition hazard (IP 5X).
exist (see Table 9):
The material used for the enclosure is central
6.1 Type of Protection “tD” significant. It must be subjected to specific
material tests. Despite the ageing process under-
In Europe, this is generally regarded to be the most gone by the material and the expected mechanical
important method for power engineering equipment. stresses, the enclosure must ensure the required
dust protection.
EN 50281-1-1 defines the type of protection Possible materials are:
for electrical equipment: “Protection by Enclosure.” > Metals (such as coated steel, stainless steel,
Two degrees of dust protection are defined for light metal)
dust explosion protection: > Glass (for enclosure parts, eg. inspection
1. Dust-tight: for the use of equipment in Zone 20, windows)
Zone 21 areas and even in Zone 22 areas, in the > Moulded plastic
case of the presence of conductive dust.
2. Dust-protected: for the use of equipment in Metals used for this purpose may have to be sub-
Zone 22 areas, in the case of the presence of jected to an impact test at low temperatures,
non-conductive dust. as some metals (light metals) have less favourable
mechanical stress at low temperatures than
The type of protection "tD" requires the limitation at higher ones.
of the surface temperature of the enclosure and
the limitation of dust ingress into the enclosure In addition, light metal may contain a maximum
(dust-tight and dust-protected enclosures): of 6 % magnesium, as it otherwise tends to form
sparks upon impact with materials such as rusty
> Dust-tight enclosure iron. Glass must withstand a thermal shocktest
An enclosure which prevents the ingress of all without cracks or without such extensive damage
observable dust particles (IP 6X). that it breaks during a subsequent impact test.
This means that a safe area is established
inside the enclosure. Please note that as com-
bustible dust particles are approx. 20 to 40 µm
in size and thus below the gap of flameproof
joints required by EN 50018 for flameproof
enclosures. Flameproof enclosures are not in
themselves dust-tight and must be separately
tested and certified according to this condition.

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 17

17

6.1.1 Enclosures of Moulded Materials material to become brittle which would eliminate
the required IP protection.
Thermal Endurance
Plastic materials must certainly fulfil the most For electrical equipment of Category 3D, it is
complex requirements. For electrical equipments sufficient for the material to have a TI at least 10 K
of Categories 1D and 2D, the temperature index higher than the temperature at the hottest point
“TI” must be known, according to EN 50281. This of the enclosure. Proof of a continuous operating
figure allows conclusions about the long-term temperature (COT) which fulfils the same
mechanical performance of moulded materials to requirement as the TI is also sufficient. No thermal
be drawn. The temperature index corresponds to endurance test is carried out in this case.
the 20,000-h point on the thermal endurance
graph without loss of flexing strenght or tenside
strenght excluding 50 %. This figure must be
20 K higher than the temperature at the hottest
point of the enclosure. In addition, the moulded
material must be proven to have sufficient
thermal resistance for the intended application.
Enclosures or parts of enclosures made of moulded
materials for electrical equipment from the
Categories 1D and 2D must be subjected
to thermal endurance tests according to EN 50014
(artificial ageing). The ageing process caused by
extreme temperatures must not cause the moulded

Table 9: Types of Protection for Use in the Presence of Combustible Dust in the Current Standards

Symbol Principle Type of Protection Current Status at IEC Future Status at IEC Status at CLC

tD IP-enclosure IEC 61241-1-1 IEC 61241-0 EN 50281-1-1

(tightness and IEC 61241-1
IP6X/5X
temperature limitation)

pD Pressurization IEC 61241-4 IEC 61241-2

+p (2001-03)

iD Intrinsic safety 31H/171/CDV IEC 61241-11

I < MIC
TG

mD Encapsulation 31H/153/CDV IEC 61241-18

(moulded compound)

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 18

dust-explosion protection
6 dust types of protection
18

Seals
Type of protection “protection by enclosures”
depends on the elastomeric seals used. These are
evaluated in accordance with Annex B3.3 of
EN 50014. This is an ageing test using specially
shaped test objects (ISO 48/ ISO 1818) which tests
the increase in hardness of the material. This
figure must not exceed 20 % difference between
Table 10: Summary of Requirements for Electrical Equipment the initial and the final figure. Materials that
Requirements: Cat. 1 + 2 – Zone 20+21 Cat. 3 – Zone 22 have hardened to a greater degree may lose their
No dust infiltration in enclosure IP6X IP5X
sealing properties.

No dust infiltration IP6X IP5X Static electricity

at cable entries
An electrostatic discharge is a “very effective”
Propagating brush discharges Insulation resistance ≤ 10 9 Ω ignition source. When moulded materials is used
must be avoided Breakdown voltage ≤ 4 kV for enclosures, the outer surface must be
Thickness of insulation ≥ 8 mm prevented from becoming charged. Otherwise, one
Laser radiation (in accordance with 5 mW/mm2 continually
of the following types of discharge will occur:
EN 50281-1-1) 0.1 mJ/mm2 impulses > Spark discharge
This type of discharges takes place between
Ultrasonic (in accordance with 0.1 W/cm2 / 10 MHz continuous grounded and ungrounded components and is
EN 50281-1-1) 2 mJ/cm2 puls
0.1 W/cm2 average
able to ignite all gases and vapours, and almost
all dust atmospheres.
External connection for as in “e” as in “n” > Brush discharge
equipotential bonding
This type of discharge is a special form of the
Plugs, sockets and connectors Separation with no voltage applied except up corona discharge. Pipes, elbows, screws, and
to 10 A, 250 V; here IP6X sufficient for tools may serve as electrodes at the maximum
separation; dust must not fall into opening field strength. This type of discharge represents
no risk to most dusts, but caution is advised
Luminaires Light source with cover, lock or warning
label; no low power sodium lamps with regard to gases and vapours.
> Propagating brush discharge
Clearance and creepage IEC 60664 IEC 60664 This is a discharge of a chargeable material
distance of connecting parts
with a low layer thickness (< 8 mm) on a substrate
Certification required yes no with adequate conductive.

Label: CE compliance according

to Directive 94 /9 /EC

Conformity to standards

Surface temp. in °C, T … °C T … °C

(not temperature class)

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 19

19

An example: Moulded materials in the pipes of Table 11: Summary of the Requirements for Rotating Electrical Machines,
pneumatic conveyor systems initially receives a Type of Protection “tD”
strong electrostatic charge from friction on the Requirements Cat. 2 – Zone 21 Cat. 3 – Zone 22
inside. This charge produces an influence-charge on
Dust tightness of enclosure IP6X IP5X
the external surface, which is coated with plastic
material and covered dust. This double layer of Magnesium content in enclosure material ≤ 6% ≤ 6%
charge may contain large amounts of energy. If
Thermal properties of non-metallic as in “e” as in “n”
one short-circuits both sides of the doubly charged enclosure materials
layer, all the stored energy is violently discharged.
This causes brightly lit discharge channels to Insulation resistance of enclosure, ≤ 10 9 Ω ≤ 10 9 Ω
fan guards
form on the surface of the plastic material. This
discharge may contain several joules of energy, so Insulation resistance of the fan wheel ≤ 10 9 Ω ≤ 10 9 Ω
that nearly all gases and vapours and the majority at all speeds
of dusts will be ignited. However, propagating
External connection for as in “e” as in “n”
brush discharges are relatively rare in practice.
equipotential bonding

The following measures can prevent this type of Dust tightness of entries IP6X IP5X
discharge process such as these :
Degree of protection of the external fan as in “e” as in “e”
> Adjusting the surface resistance to 10 9 Ω and
grounding the plastic material. Protective cover for V1 (air inlet on top) as in “e”
> Limiting the breakdown voltage of the non-
Fan and cover construction and mounting as in “e” as in “e” /”n”
conductive material to 4 kV.
> Avoiding thicknesses < 8 mm for the non-conduc- Clearances in ventilation system as in “e”
tive material.
> Limiting isolated capacities to < 10 pF. Magnesium content in the material ≤ 6% ≤ 6%
of the fan
> Increasing humidity to > 65 % in order to reduce
the insulation resistance of non-conductive Clearance and creepage IEC 60664 IEC 60664
materials. distances of connecting parts

Certification by notified body required yes no

CE conformity

Conformity to standards

Surface temperature in °C T …°C T …°C

(not temperature class)

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 20

dust-explosion protection
6 dust types of protection
20

Mechanical Stability Cable Glands

For equipment from Categories 1D and 2D, Power supply and instrumentation cables
mechanical tests are carried out in accordance are connected to the explosion-protected electrical
with EN 50014. The enclosures must withstand an equipment. The cable entries must be in
impact energy of 7 joules. accordance with Annex B of EN 50014. This means
that the certified “Increased safety” cable glands
If the enclosure contains light transmitting parts, for hazardous areas may be used. It must be noted,
they are subjected (without basket guard) to a test however, that the Ex e cable entries require IP 54,
with 4 joules or (with basket guard) to one with whereas for dust explosion protection, equipments
2 joules. from Categories 1D and 2D require IP 6X and
devices from Category 3D IP 5X. In addition, test
Tests such as these are to be carried out after of increase in hardness is required (see Seals).
thermal shock resistance test at a temperature This verification can be provided by the
10 to 15 K higher than the maximum operating tests mentioned here or by data sheets from the
temperature and 5 to 10 K below the lowest gasket manufacturer.
operating temperature.
6.2 Protection by Pressurization “pD”
After the mechanical stability test, the degree
of protection IP according to Table 10 has to be This type of protection, based on Pressurized
fulfilled. apparatus “p”, could become important in the
protection of switch cabinets in hazardous areas,
In the case of portable electrical equipment, for example. Equipment of the type “pD” can
a drop test in accordance with EN 50014 must also only be used in Zone 21 and Zone 22 (not in Zone
be carried out. 20). The purging phase required for gas explosion
protection is not permitted for dust explosion
protection, as the swirling up of deposited dust
Table 12: Requirements on Failure of Pressurization
could produce a hazardous explosive atmosphere.
Section 4.3 of the standard explicitly requires
Type of apparatus in the enclosure
that before the pressurization system is switched
Zone operational ignition source no ignition source in normal operation
on, the interior of the equipment be cleaned and
20 “pD” not applicable “pD” not applicable all dust that accumulated there after switching off
the external ventilation be removed.
21 Switching off as in 7.5.1.1 Warning as in 7.5.1.2

22 Warning as in 7.5.1.2 Internal pressurization not required The measures to be taken when the pressurization
equipment fails are graduated according to
zone and the presence of operational ignition
sources (see Table 12).

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 21

21

6.3 Intrinsic Safety “iD” > Temperature limits on all outer surfaces
of apparatus or their parts whose power limits
The current draft (CD) largely corresponds to the exceed the operational limits required in
4th edition of IEC 60079-11: 1999 for gas IEC 61241-11. The surface may consist of an
explosion protected apparatus with type of pro- enclosure or an encapsulation.
tection Intrinsic safety “i”.
Work is continuing on the standard for the intrinsic
The final version should refer for the most part safety “iD” ignition protection type, therefore
to the directly valid sections of Standard we refer the reader to current articles in our Ex-
IEC 60079-11 without repeating the text of this Magazine.
standard. This is what is to be expected in
practice when the design of “iD” apparatus is 6.4 Encapsulation “mD”
derived from existing and already tested
intrinsically safe apparatus. The dust type of protection “mD” in accordance
with IEC 61241-18 is to be based primarily on type
The preliminary translation of the introduction of protection “m” according to IEC 60079-18,
to the future standard IEC 61241-11 mentions the which is currently being revised.
following basic requirements:
> Electrical circuits must fulfil the requirements Further proceedings on the draft of IEC 61241-18
of Group IIB from IEC 60079-11, in order to will therefore be determined by the development
prevent ignitable sparks. of the new IEC 60079-18.
> Normally, degree of protection IP 6 X or encap-
sulation is required to ensure that clearances
and creepage distances are not effected.
> Power limitation for equipment or their parts
that are not proteced by an enclosure or
encapsulation (e.g. for non-insulated sensors).
This is the intended to prevent that a dust
layer ignites due to a direct transfer of power by
conductive dust and to prevent ignition due to
heat on the surface of components.

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 22

dust-explosion protection
7 equipment selection
22

7. Equipment Selection The “Essential Health and Safety Requirements”

from Directive 94/9/EC deal with the problem of
After assessment of the installation and dust deposits in Annex II, Paragraph 1.2.4. In
its possible risk, the user should consider the addition to requiring the removal of dust layers,
following criteria when selecting electrical this states that the surface temperature of
equipment: equipment and equipment parts be well below
> Determination of the equipment category in the ignition temperature of the dust layer.
accordance with the hazardous zone. An accumulation of heat must be expected and
> Assessment of the properties of existing dust. should be countered with using temperature
> Maximum permissible surface temperature of limitation. Dust accumulations should, if possible,
the equipment, taking into consideration be limited or avoided entirely. For the equipment
the type of dust, the ignition temperature of manufacturer, this means the equipment must be
the dust cloud and, if dust deposits cannot be produced in such a way that dust deposits do not
excluded, the ignition temperature of the arise and/or the equipment is easy to clean.
dust layer.
> EN 50281-1-2 deals wih the selection
The selection of the equipment category can of electrical equipment and specifies that
be carried out as described in Table 13. This independent of classification into zones, the
defines the design of the enclosure in accordance possibility of the equipment being covered
with the requirements of Clause 4,5 and 6 of or completely submerged by dust must be taken
EN 50281-1-1. The dust-tightness tested using the into consideration, unless this situation can
procedure described in EN 60529 for Category 1D, be avoided.
must be taken into account. > EN 50281 does not currently regulate the
question of how dust deposits on electrical
equipment influence the safety level. For equip-
ment from Category 3D, there is no requisite
consideration of possible faults. This would
mean that equipment from Category 3D would
be subject to a thermal assessment – in ex-
treme cases when totally submerged in dust –
however that common faults need not be
Table 13: Selection of Dust Explosion Protected Apparatus
taken into consideration.
Type of Dust Zone 20 Zone 21 Zone 22

conductive Category 1D Category 1D Category 1D Zone 21 presents a similar problem. Is the

Temperature limitation or 2D or 2D inside of containers in which combustible dust is
when excessive deposits
stored also a part of this zone? The situation
can be present
is clearer in the case of Zone 20, as due to the
non-conductive Category 1D Category 1D Category 1D, definition complete sumerging of the equipment
Temperature limitation or 2D 2D or 3D must be taken into account.
when excessive deposits
can be precent

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 23

23

Figure 7: Correlation between the Maximum Permissible Surface Temperature and the Thickness of Dust Layers

The self-ignition of dust deposits is a critical other areas by way of transportation facilities.
problem. These processes are often caused by During this process, the flames swirl up unburned
exothermal reactions involving oxygen from dust, which in turn takes deposited dust with it.
the surrounding air. It could be a chemical reaction A sudden change in the volume of the dust cloud
(oxidation), a physical reaction (adsorbtion) or a as it enters a larger room (e.g. a silo) can produce
decomposition process (mainly in the case of a hazardous explosive atmosphere. The flames
organic dusts). Self-ignition is determined of the cause ignition.
temperature of the surrounding area, of the
geometric factors and of the volume of the dust. The ignition temperature of a dust layer is
The reaction heat produced during decomposition determined using the method from EN 50281-1-2.
of materials can produce carbonisation gas, which The determination of the maximum surface
in turn can lead to an explosive gas/air mixture. temperature that an electrical apparatus can
achieve must be done by the manufacturer, with
Not every case of dust ignition necessarily leads any possible faults taken into consideration.
to an explosion. Dusts with low rate of pressure Temperature limitation measures should be used
rise may first of all be a dust fire. Under certain to counter these faults (electrical/thermal fuse).
conditions, an explosion may occur, often in The maximum surface temperature is measured
a completely different location than the ignition. as specified in Clause 10 of EN 50281-1-1.
The fire can spread from the place of origin to

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 24

dust-explosion protection
7 equipment selection
24

Figure 8: Determining the Maximum Surface Temperature When determining the maximum permissible
TL Under a Dust Layer of Thickness L in mm surface temperature (in relation to the
surrounding dust), two figures should be noted:
1. Maximum permissible surface temperature
when a dust cloud is present (calculation in
L accordance with 6.1 of EN 50281-1-2).
L The ignition temperature of the dust cloud must
be taken into account.
2. Maximum permissible surface temperature
when a dust layer is present. When making
the determination, one must take the ignition
L L temperature of a dust layer (which is dependent
on the thickness of the dust layer) into account:
> For dust deposits up to 5 mm thick, the
calculation must be made in accordance with
L 6.2.1 of EN 50281-1-2.
> For dust deposits > 5 mm -- 50 mm, the curves
in Figure 7 may be applied.
The redutions in temperature plotted here were
determined empirically for dust layers of up
to 50 mm on top of electrical equipment. The
curves take into account both the reduction,
specific to dusts, of the ignition temperature
with increasing layer thickness, and also an ex-
pected increase of the temperature of the
electronic apparatus, due to the reduction of the
heat flow. In addition, the curves include the
usual safety reduction of 75 K.
Here it must be stated explicitly that this does
not take into account an electrical apparatus
submerged completely in dust.
> Determining a surface temperature for
dust deposits > 50 mm: According to the
currently valid requirements in Clause 6.3 of
EN 50281-1-1, if dust deposits of excessive
thickness are present, the equipment in
question must be tested in a laboratory using
the relevant dust (see Annex A of the above-
mentioned standard).

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 25

25

In the future, manufacturers will have the option, The following verification from 1 and 2 must
during the type testing, of determining a surface be made by the user!
temperature TL under a deposit of thickness
L (orientated toward the thickness of the layer The maximum permissible surface temperature,
during actual use), which may be stated on in relation to the ignition temperature of a dust
labels (Figure 8). Section 5.2 of IEC 61241-0 cloud Tic and/or the ignition temperature of a
states: “In addition to the maximum surface dust layer Til of the surrounding dust is determined
temperature TL required in 5.1, the maximum as follows:
surface temperature may be stated for a given 1. Maximum permissible surface temperature in
depth of layer, TL, of dust surrounding all sides case of dust clouds Tmax = 2/3 Tic
of the apparatus, unless otherwise specified 2. Maximum permissible surface temperature in
in the documentation, and marked according to case of dust layers (5 mm thickness)
29.2(8)”. For the determination of the temperature Tmax = Til – 75 K
TL, 23.4.5.2 requires: “…the electrical
apparatus to be tested shall be mounted and Example: flour
surrounded by a layer depth "L" as stated by the Tic ≥ 380°C and Til ≥ 300°C
manufacturers specification. The measurement Tmax (1) = 2/3 x 380°C = 253°C
for the maximum surface temperature shall Tmax (2) = 300°C – 75 K = 225°C
be made …using a dust having a thermal con-
ductivity of no more than 0.003 kcal/m · °C · h.” Accordingly, the surface temperature of the
The user must take note of Clause 6.3.3.4 of electrical equipment in this particular case must
the installation standard 61241-14: “Where the not exceed the value of 225°C; this must be
apparatus is marked TL for a layer depth the guaranteed by the manufacturer (see “Determi-
ignition temperature of the combustible dust, at nation of the Maximum Surface Temperature”
a layer depth L, must be applied in place of T5 mm.” above).

Figure 9: Explosion Protected Luminaire 6600 Series for Use in Zone 21 (Category 2D) and Zone 22 (Category 3D).

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 14:26 Uhr Seite 26

dust-explosion protection
7 equipment selection
26

Radiation-Emitting Equipment Plugs and Sockets, Plug Connectors

Optical radiation is a peripheral phenomenon in In Zone 20, plugs and sockets are not permitted.
the field of dust explosion protection. The first In Zone 21 and Zone 22, for electrical equipment
factor to be considered when determining the limit from Categories 2D and 3D, the following require-
value is: How high is the power density? ments apply:
> Plugs and sockets shall either be interlocked
If the power density is ≤ 0.1 W/cm 2, no further mechanically, or electrically, or otherwise
assessment is necessary. Pulse-shaped signals are designed so that they can not be separated
assessed according to the energy density. In when the contacts are energized or in such a
addition, however, the energy density as an average way that they can only be separated when the
of the pulse-pause ratio must be taken into power is off, or
account. Besides this, an assessment of possible > In accordance with 9.2 of EN 50014, plug
faults is to be carried out in order not to exceed the connectors must be fixed together by special
limit values for equipment from Categories 1D fasteners and a warning label affixed to them:
and 2D. The figure for the pulse-pause ratio, which “DO NOT SEPARATE WHEN ENERGIZED”.
is the basis of the calculation, is particulary im-
portant. Radiation in the optical range (especially Supplementary Requirements
if it is focussed) may ignite the dust/air mixture. EN 50281-1-1 contains several supplementary
Laser radiation can cause ignition from a requirements for specific electrical equipment
great distance, even when it is not focussed. from Category 2D which must be taken into
account. Here are some important examples:
Limit values to be ensured: > Rotating electrical machines, such as shaft
> Power density ≤ 5 mW/mm2 for driven external fans used for cooling, must be
continuous wave lasers surrounded by a fan hood.
> Pulse energy density ≤ 0.1 mJ/mm2 for > Switch gear with contacts immersed in flam-
pulsed lasers mable dielectrics is not permitted. Enclosures
must be locked with isolators or labeled with a
In the case of ultrasonic transmitting warning lable:“DO NOT OPEN WHEN ENERGIZED”,
(e.g. sensors), a large percentage of the energy if contactors or other remote-controlled com-
emitted by the ultrasonic transducer is absorbed ponents are included in them. If a disconnector
by dust. This causes heating of the dust particles, is built-in, it must disconnect all poles and be
which in extreme cases even reach the ignition set up so that its contact position is visible, or
temperature. Limit values to be observed: their position is reliably indicated. Any interlock
> Power density ≤ 0.1 W/cm2 between such disconnector and the cover
> Pulse energy density ≤ 2m J/cm2 or door shall only permit the door to be opened
when the separation of the disconnector
contacts are effective.

Additional internal supplementary enclosures

for parts which remain energized when the
enclosure is opened.

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 27

27

> Fuses: unopenable when energized, or

warning label as for switch gears.
> Luminaires: lamps containing free metallic
sodium (e.g. low-pressure lamps according to Table 14: Contents of Operating Instructions
EN 60192) are not permitted. According to EN 50281-1-1

> Putting into service

Connecting Components
As in gas explosion protected areas, electrical > Use
equipment is connected to the outer power circuit
> Assembling and dismantling
using terminals.
> Maintenance
The equipment can also be connected using
a cable that is fixed integrated. Apparatus with > Installation

fixed connected cables are an exception when > Electrical characteristics

only one end of the cable is permanently
connected. These devices must be labeled with > Specific conditions
the symbol X.
The user must be given instructions for the
unattached end of the cable (e.g. within Zone 21, Table 15: Marking of Equipment
the free cable end must be plugged into an EN according to EN 50281-1-1
apparatus of Category 2D).
> Name and address of manufacturer
(trademark)
Operating Instructions and Marking
Table 15 shows the marking for electrical equipment > Series and type identification

in accordance with EN 50281 and Directive

> Serial number
94/9/EC. Data relevant to explosion protection,
such as equipment group, category and maximum > Electrical characteristics
surface temperature should be displayed as shown
> Maximum surface temp.T
in the following example: II 2 D T 135 °C.
>
No classification of dusts into temperature
> Equipment Group, in this case II
classes is planned. Unlike gases, dusts require a
margin of safety between surface temperature and > “D” for dust
ignition temperature of a dust cloud and a
dust layer. > Category

> Testing laboratory and certification number

Each equipment has a set of operating (year/Id. number.)
instructions which must contain the elements
shown in Table 14. > Year of manufacture

>

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 28

dust-explosion protection
8 installation and maintenance
28

8. Installation and Maintenance Cabel installation

> Cables must be placed so that they cannot
The protective measures described in Section 4 become electrostatically charged by moving dust
alone are not sufficient to prevent an explosion. (friction effect).
Installation carried out according to requirements, > Cables runs shall be arranged insofar possible
punctual, correct and consistent maintenance that no large dust deposits can be collected.
are all crucial for maintaining safe operations Sufficient access for cleaning must be possible.
(EN 50281-1-2). > If possible, cables shall not pass through areas
with potentially explosive dust atmosphere if
During installation, the manufacturer’s they are not connected to this area.
operation conditions in the operating instructions > If dust layers form on cables, preventing free air
must be followed carefully. circulation, a reduction of the current carrying
capacity of the cable shall be considered.
8.1 Installation of Cables This applies especially to dusts with a low
ignition temperature.
Selection of Cables > If cables pass through walls or other structures,
In general, the common types of cables are this must be done so as to prevent the passage
permitted, if they are installed into screwed, solid, or collection of combustible dust.
drawn or steamed welded conduits. Cables whose > For transportable electrical equipment, a
construction ensure that they are dustproof and suitable cable type must be used. For these
suitable for mechanical stress may also be used. purposes, often a suitable connection box must
Examples are: be placed between the moving and fixed
> Cables with thermoplastic or elastomeric wire cable routing.
insulation, screened or armoured cable and an > If metal conduit is used, care should be taken
outer sheath of PVC (poly-vinylchloride), PCP to ensure that there is no possibility of
(polychloroprene rubber), or a similar material. cabel damage at the connecting points, that the
> Cables with a seamless aluminium sheath with connecting points are dustproof, that the im-
or without armouring. permeability of the connected equipment is not
> Mineral-insulated cables with metal sheath. reduced, that the connecting points are included
Note: These cables and wires may have to in the potential equalisation.
be operated below their rated valuues to limit the
surface temperature from exceeding the
required values.
> When cables are externally provided with
protection, or when there is no danger of me-
chanical damage, cables with thermoplastic
or elastomeric insulation and a sheath of PVC,
PCP, or a similar material are permitted.

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 29

29

Cable Glands 8.3 Documentation

The requirements for the entries into dust
explosion protected equipment from Categories 1D EN 50281-1-2, 10.3:
and 2D are almost identical with those for a gas “Plans of each site shall be maintained to show
explosion protected glands, type of protection the following:
“Increased safety”. Both must be in compliance > The classification and extent of the
with Annex B of EN 50014. hazardous areas; the information shall include
the zoning and maximum layer thickness, if
The only differences are in the degree of greater than 5 mm.
protection and in approval: > Records of the types and marking details of
> Dust-Ex: IP 6X, certification for Zone 20 and/or protected apparatus and sufficient information
Zone 21 to enable them to be maintained properly.
> EEx e: IP 54, certification for Zone 1 and Zone 2 > Types, routes and details of wiring system.”

Cable glands must be assembled and mounted so This task is in conformity with the requirement
that they do not compromise the equipment’s dust of the Directive 99/92/EC, which obligates
tightness. They can also be permanently the employer to draw up an explosion protection
connected to the equipment, in which case they document. The content of the document
are certified together with the equipment. should indicate:
> The explosion risk have been determined
8.2 Maintenance and Servicing and assessed.
> Adequate measures will be taken.
In addition to the protective measures already > Work equipment and warning device are
taken, an organisational plan must be drawn up design, operated and maintained with due
for the installation. regard for safety.
> Cleaning, removal of dust deposits. > Provisions to ensure that the equipment is
> Inspection and maintenance of equipment and used correctly.
protective systems.
> Testing of earthing, especially for the
parts of the equipment that could become
electrostatically charged.

These measures serve firstly to reduce the risk

of explosion and secondly to ensure the effective-
ness of the constructional protective measures.

“The inspection and maintenance of electrical

apparatus for use in combustible dust shall only be
carried out by personnel who are familiar with
the concept of protection.” (EN 50281-1-2:1998, 12.1)

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:48 Uhr Seite 30

dust-explosion protection
9 product overview
30

Some Examples of
9. Product Overview
Dust Explosion
Protected Products
R. STAHL has a fully certified product range for
ECOLUX 6608 dust hazardous areas in your installation.
Emergency Luminaire
We take dust explosion protection just as seriously
as gas explosion protection. We can offer you a
specially adapted solution for almost every
Optical Beacon 6161
Traffic Light 6091
application. At a minimum, all dust explosion
protection products comply with the regulations of
Group 3D; that is, they can be used in Zone 22
(non-conductive dusts).

The following equipment series and systems are

certified for both Zone 21 and Zone 22:
Control System
Series 8040 > Luminaire Series 6600 and 6608,
Lighting and Heating Panel Compact Luminaire 6100 and 6108
Series 8146 > Tank Inspection Light 6122 and
Optical Beacon 6161
> Traffic Light 6091
> Control System ConSig 8040
Switch- and
> Position Switches 8060 and 8070
Distribution Board > Junction and Terminal Boxes Series 8118
CUBEx > Control Panel and Terminal Boxes Series 8146
and 8125
> Ex d Enclosure System CUBEx
> Safety Barriers INTRINSPAK
> Isolators Series IS pac
Safety Barriers > Remote I/O System I.S.1
INTRINSPAK > SolConeX Plugs and Sockets
EX i Isolators IS pac

Remote I/O System I.S.1

Plugs and Sockets
SolConeX

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:49 Uhr Seite 31

31

Your Safety – Our Reality

If your installation is faced with the risk of a dust

explosion, R. STAHL offers the expertise you need.

R. STAHL has decades of experience in the field of

electrical explosion protection.

We will be glad to help you solve your safety

problems. In addition to a comprehensive range of
electrical equipment, we offer you expert advice
and training in the dust explosion protection field.

Get in touch with us.

You will find a downloadable list of our dust

explosion protection products in PDF form at :

www.dust-ex.stahl.de

R. STAHL Explosion protection

staubEX_e_04_10_04.qxd 21.10.2004 12:49 Uhr Seite 32

VISUELL, Stuttgart

R. STAHL Schaltgeräte GmbH

Am Bahnhof 30, 74638 Waldenburg, Germany
Phone +49 7942 943-0
Fax +49 7942 943-4333

www.stahl.de

ID-NR. 00 006 84 77 0
S-PB-dustex-00-en-04/2004 · Printed in the Federal Republic of Germany