Fmds 0501 Electrical Equipment in Hazardous (Classified) Locations

FM Global
Property Loss Prevention Data Sheets 5-1

September 2006
Page 1 of 37
ELECTRICAL EQUIPMENT IN HAZARDOUS (CLASSIFIED) LOCATIONS
Table of Contents
Page
1.0 SCOPE ................................................................................................................................................... 3

1.1 Changes .......................................................................................................................................... 3
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 3
2.1 Introduction ...................................................................................................................................... 3
2.1.1 Referenced NFPA or International and National Standards ................................................. 3
2.1.2 Exceptions to Application of Data Sheet 5-1 ........................................................................ 3
2.2 Occupancy ....................................................................................................................................... 4
2.2.1 Classification of Hazardous Locations: Class I and Class II Hazardous Locations ............. 4
2.3 Equipment and Processes .............................................................................................................. 6
2.3.1 General .................................................................................................................................. 6
2.3.2 Specific Electrical Wiring and Equipment Requirements ...................................................... 7
2.3.3 Purged and Pressurized Enclosures for Electrical Equipment in Class I and Class II
Hazardous (Classified) Locations ....................................................................................... 12
2.4 Operation and Maintenance .......................................................................................................... 14
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................. 14
3.1 General .......................................................................................................................................... 14
4.0 REFERENCES ..................................................................................................................................... 14
4.1 FM Global ...................................................................................................................................... 14
4.2 NFPA Standards ............................................................................................................................ 14
4.3 Others ............................................................................................................................................ 14
APPENDIX A GLOSSARY OF TERMS ..................................................................................................... 15
APPENDIX B DOCUMENT REVISION HISTORY ..................................................................................... 15
APPENDIX C SUPPLEMENTARY INFORMATION ................................................................................... 15
C.1 General ......................................................................................................................................... 15
C.2 Explanatory Material ..................................................................................................................... 15
C.2.1 Class I Hazardous Locations .............................................................................................. 16
C.2.2 Class II Hazardous Locations ............................................................................................. 17
C.2.3 Nonclassified Locations ...................................................................................................... 17
C.2.4 Purged and Pressurized Enclosures as covered by NFPA 496 ......................................... 18
C.2.5 Intrinsically Safe Electrical Equipment ................................................................................ 18
C.2.6 Non-Incendive Electrical Equipment ................................................................................... 19
C.2.7 Explosionproof Equipment .................................................................................................. 19
C.2.8 Dust-ignitionproof Equipment ............................................................................................. 19
C.2.9 Other Protected Types of Electrical Equipment ................................................................. 19
C.3 Group Classification ...................................................................................................................... 20
C.4 NEMA Classifications for Enclosures for Electrical Equipment .................................................... 21
C.5 FM Approvals ................................................................................................................................ 21
C.6 Theoretical Background Information ............................................................................................. 22
C.6.1 General ............................................................................................................................... 22
C.6.2 Intrinsically Safe Equipment ................................................................................................ 23
C.7 Requirements in Countries Outside of the United States ............................................................. 23
C.8 NFPA Standards ............................................................................................................................ 24
C.9 Portable Electronic Products ........................................................................................................... 24
©2006 Factory Mutual Insurance Company. All rights reserved. No part of this document may be reproduced,
stored in a retrieval system, or transmitted, in whole or in part, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without written permission of Factory Mutual Insurance Company.
5-1 Equipment in Hazardous (Classified) Locations
Page 2 FM Global Property Loss Prevention Data Sheets
APPENDIX D BIBLIOGRAPHY ................................................................................................................. 25

APPENDIX E THE THREE-ZONE CLASSIFICATION SYSTEM AND THE NATIONAL ELECTRIC
CODE ................................................................................................................................... 25
List of Figures
Fig. 1. Areas near indoor hazardous processes or equipment handling heavier than air vapors
where special types of electrical equipment are needed. .................................................................. 5
List of Tables
Table 1. Area Classification of Locations Containing Flammable Gas or Vapor Atmospheres (Class I) ...... 4
Table 2. Classification Guidelines Based on Depth of Dust Accumulations ................................................. 6
Table 3. Protected Types of Electrical Equipment for Class I Locations per the NEC or
Comparable Hazardous Locations per IEC or CENELEC Standards ............................................. 7
Table 4. T Codes (Temperature Identification Numbers) ............................................................................... 8
Table 5. Equipment Recommended for Locations Containing Flammable Gases or Vapors (Class I)* ....... 9
Table 6. Surface Temperature Limits ........................................................................................................... 11
Table 7. Equipment Recommended for Locations Containing Combustible Dusts (Class II)* ................... 11
Table 8. Group Classifications for Flammable Gas and Vapor Atmospheres ............................................. 20
Table 9. Group Classifications of Dust Atmospheres per NEC Article 500 ................................................. 20
Table 10. Ignition Characteristics of Selected Gases ................................................................................. 22
Table 11. Minimum Ignition Energy of Selected Dusts1 .............................................................................. 23
©2006 Factory Mutual Insurance Company. All rights reserved.

Equipment in Hazardous (Classified) Locations 5-1
FM Global Property Loss Prevention Data Sheets Page 3
1.0 SCOPE
This loss prevention data sheet provides recommendations for preventing electrical systems or equipment
from igniting flammable gases, flammable vapors and combustible dusts that may be released into the
atmosphere, or that may be normally present in or near processing equipment.
The following FM Global loss prevention data sheets should be consulted for specific guidance at specific
occupancies: Data Sheet 7-1, Fire Protection for Textile Mills (locations involving combustible fibers or flyings
in textile processes); Data Sheet 7-9, Dip Tanks, Flow and Roll Coaters and Oil Cookers; Data Sheet 7-13,
Mechanical Refrigeration; Data Sheet 7-27, Spray Application of Flammable and Combustible Materials;
Data Sheet 7-30N, Solvent Extraction Plants; Data Sheet 7-32, Flammable Liquid Operations; Data Sheet
7-55/12-28, Liquefied Petroleum Gas.
This data sheet does not address Class III (easily ignitable fibers and flyings) hazardous locations.
1.1 Changes
September 2006. Added information on the acceptability of portable electronic products to Appendix C.
2.0 LOSS PREVENTION RECOMMENDATIONS
2.1 Introduction
2.1.1 Referenced NFPA or International and National Standards

2.1.1.1 Although recommendations in this data sheet are primarily based on the NEC, there are exceptions
and additions. If an application is not covered in the data sheet, refer to one of the following NFPA or
corresponding international and national standards:
NFPA 70, Articles 500 and 505, National Electrical Code, 1999.
IEC 60079-10:1995 or EN 60079-10:1996, Electrical apparatus for explosive gas atmospheres — Part 10:
Classification of hazardous areas.
IEC 61241-3:1997, Electrical apparatus for use in the presence of combustible dust — Part 3: Classification
of areas where combustible dusts are or may be present.
NFPA 496, Purged and Pressurized Enclosures for Electrical Equipment, 1998.
NFPA 497, Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors and of
Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas, 1997.
NFPA 499, Recommended Practice for the Classification of Combustible Dusts and of Hazardous (Classified)
Locations for Electrical Installations in Chemical Process Areas, 1997.
CSA Standard C22.1-98, Canadian Electrical Code, Part 1.
2.1.2 Exceptions to Application of Data Sheet 5-1

2.1.2.1 The NEC or other corresponding international and national standards do not make any explicit
exceptions to the use of hazardous location electrical equipment in areas where only small amounts of
flammable material are handled. However, it is reasonable to conclude that in many cases where only small
amounts of ignitable materials are involved, the cost of providing FM Approved (see Appendix A for
definition)or listed electrical equipment would not be justified.
Note: Reference to other corresponding international and national standards within this guideline is primarily
intended to mean IEC (International Electrotechnical Commission) or CENELEC (European Committee for
Electrotechnical Standardization) standards, but not exclude other national standards that typically are based
on these standards or occasionally the NEC with national deviations.
Because the result of a fire ignited by electrical sources will vary depending on site specific circumstances,
no all-encompassing guidance will be provided here to distinguish the specific cases when ordinary electrical
equipment would be acceptable in an area that might theoretically be considered a hazardous (classified)
location. However, to help in the application of engineering judgement, a few examples will be given of cases
where Approved or listed equipment may not be required.

Example 1:
Small quantities of low flash point flammable liquids are handled in equipment or containers such that the
maximum ignitable quantity in the event of electrical ignition would not exceed 5 gallons (19 liters), and the
ignition of that quantity would not cause a rapid escalation of fire events. Approved containers should be
used where transporting or dispensing of the liquid is involved.
Example 2:
Small quantities of flammable gas are used on a regular basis in a given area, such as in a 1 lb (0.5 kg)
cylinder of propane used in a workshop brazing torch.
Example 3:
Larger quantities of flammable gas are used as fuel for mobile equipment, such as propane or natural gas
to power a forklift truck, or as part of a portable acetylene welding kit. The mobile equipment may be brought
to areas that would not normally require hazardous location electrical equipment.
Example 4:
Fine combustible dust is produced and accumulates, but in relatively small quantities, and without producing
a potential explosion hazard, such as at a sanding machine in a woodworking shop.
2.2 Occupancy
2.2.1 Classification of Hazardous Locations: Class I and Class II Hazardous Locations

Note: The following definitions and application guidelines are primarily based on the historical ‘‘division’’
classification method as traditionally used within the United States (U.S.) and covered by Article 500 of the
NEC. The 1996 Edition of the NEC (Article 505) introduced an alternative classification method, the so-called
‘‘zone’’ classification method for Class I (i.e., flammable gas or vapor) atmospheres only, which is consistent
with the approach essentially used throughout the rest of the world. Only one of these classification methods
may be used within the U.S. for a specific location (i.e., cannot mix methods) and implementation of Article
505 must be under the supervision of a qualified registered professional engineer. The Canadian Electrical
Code, which had been similar to the NEC, now requires the zone classification method for Class I
atmospheres be used for new installations. For equivalency purposes, see Table 1 for a comparison of the
Class I hazardous area classification methods as covered by the NEC and the corresponding IEC or
CENELEC standard (i.e., IEC 60079-10 or EN 60079-10) for areas where flammable gases or vapors are
or can be present.
Table 1. Area Classification of Locations Containing Flammable Gas or Vapor Atmospheres (Class I)
Standards Flammable Material Flammable Material Flammable Material
Organizations Present Continuously Present Intermittently Present Abnormally
IEC/CENELEC Zone 0 Zone 1 Zone 2
NFPA NEC Article 505 Zone 0 Zone 1 Zone 2
NEC Article 500 Division 1 Division 2
Note: The IEC and CENELEC do not use the Class I designation for areas where flammable gases or vapors may be present. That is,
the corresponding area designations would be Class I, Zone 1 (NEC Article 505) and simply Zone 1 (IEC/CENELEC) for example.
2.2.1.1 Class I Hazardous Locations

2.2.1.1.1 Locations in which flammable gases or vapors are or may be present should be classified as Class
I, Division 1 hazardous locations if the following conditions exist: 1) ignitible concentrations of flammable
gases or vapors can exist under normal operating conditions; or 2) ignitible concentrations of such gases
or vapors may exist frequently because of repair or maintenance operations or because of leakage; or 3)
breakdown or faulty operation of equipment or processes might release ignitible concentrations of flammable
gases or vapors, and might also cause simultaneous failure of electric equipment.
Note: The definition for a Class I, Zone 1 hazardous location is the same as for a Class I, Division 1 except
for an additional condition. The additional condition for a Class I, Zone 1 hazardous location is (4) if adjacent
to a Class I, Zone 0 hazardous location from which ignitable concentrations of vapors could be communicated,

unless communication is prevented by adequate positive ventilation from a source of clean air and effective
safeguards against ventilation failure are provided. Locations where flammable gases or vapors are present
continuously or for long periods of time (i.e., typically 1000 hours or more per year) are considered Class
I, Zone 0 hazardous locations. See C.2.1 for examples of Class I, Zone 0 hazardous locations.
2.2.1.1.2 Locations in which flammable gases or vapors are or may be present should be classified as Class
I, Division 2 hazardous locations if the following conditions exist: 1) volatile flammable liquids or flammable
gases are handled, processed, or used, but in which the liquids, vapors or gases will normally be confined
within closed containers or closed systems from which they can escape only in case of accidental rupture or
breakdown of such containers or systems, or in case of abnormal operation of equipment; 2) ignitible
concentrations of gases or vapors are normally prevented by positive mechanical ventilation, and which might
become hazardous through failure or abnormal operation of the ventilating equipment; or 3) that are adjacent
to a Class I, Division 1 location, and to which ignitible concentrations of gases or vapors might occasionally
be communicated unless such communication is prevented by adequate positive-pressure ventilation from a
source of clean air, and effective safeguards against ventilation failure are provided. The definition for a Class
I, Zone 2 hazardous location is essentially identical to the above definition for a Class I, Division 2 hazardous
location (i.e., simply replace the word ‘‘Division’’ with the word ‘‘Zone’’).
2.2.1.1.3 Figure 1 should be used to determine the degree of hazard at various distances from a typical
indoor vapor source expected to have a Division 1 area (e.g., open equipment or process). Figure 1 should
assist in the selection and location of equipment in Class I areas. When other applicable FM Global data
sheets provide distances for classified (hazardous) areas related to specific hazards and occupancies, refer
to them rather than to Figure 1.
Fig. 1. Areas near indoor hazardous processes or equipment handling heavier than air vapors
where special types of electrical equipment are needed.
2.2.1.1.4 Figures in NFPA 497 may be used to help determine the extent of a Class I, Division 2 or Zone
2 area for leakage sources located outdoors, in closed containers or systems (e.g., pipes, process equipment)
with or without adequate ventilation or in other closed installations that are not expected to have Division I
or Zone 1 areas. Since NFPA documents normally recommend what are considered minimum criteria,
considerable judgement may still be needed in the evaluation of a specific situation.
2.2.1.1.5 Adequate mechanical ventilation may be provided to reduce the extent of a hazardous location
or to reduce the classification level. A ventilation system can significantly reduce or even eliminate a Division
1 or Zone 1 area. Exceptions to completely eliminating a Division 1 or Zone 1 area would include the
immediate vicinities where the release of ignitable concentrations of vapor are expected under normal
conditions. (See Appendix C for examples.) Adequate ventilation requires a ventilation rate of 1 ft3/min/ft2

(0.3 m3/min/m2) of room or process area to ensure that flammable vapor concentrations do not exceed 25%
of the lower explosive limit. In addition, effective safeguards against the failure of the ventilation system
should be provided.
2.2.1.2 Class II Hazardous Locations

2.2.1.2.1 Locations in which combustible dusts are or may be present should be classified as Class II,
Division 1 hazardous locations if the following conditions exist: 1) combustible dust is in the air under normal
operating conditions in quantities sufficient to produce explosive or ignitible mixtures; 2) mechanical failure
or abnormal operation of machinery or equipment might cause such explosive or ignitible mixtures to be
produced, and might also provide a source of ignition through simultaneous failure of electric equipment,
operation of protection devices, or from other causes; or 3) where combustible dusts of an electrically
conductive nature may be present in hazardous quantities.
2.2.1.2.2 Locations in which combustible dusts are or may be present should be classified as Class II,
Division 2 hazardous locations if the following conditions exist: 1) locations where combustible dust is not
normally in the air in quantities sufficient to produce explosive or ignitible mixtures, and dust accumulations
are normally insufficient to interfere with the normal operation of electric equipment or other apparatus, but
combustible dust may be in suspension in the air as a result of infrequent malfunctioning of handling or
processing equipment; and 2) where combustible dust accumulations on, in, or in the vicinity of the electrical
equipment may be sufficient to interfere with the safe dissipation of heat from electrical equipment or may be
ignitible by abnormal operation or failure of electrical equipment.
2.2.1.2.3 The classification guidelines shown in Table 2 may be used, based on a maximum total
accumulation between cleanings on the major portions of horizontal surfaces.
Table 2. Classification Guidelines Based on Depth of Dust Accumulations

Dust Layer Thickness Division
>1⁄8 in. (3.2 mm) 1
<1⁄8 in. (3.2 mm) but surface color not discernible or surface color discernible, but a hazardous quantity 2
of dust may be released as a result of infrequent malfunctioning of handling or processing equipment
Surface color discernible and a hazardous quantity of dust cannot foreseeably be released as a result Nonclassified
of infrequent malfunctioning of handling or processing equipment.
Based on these accumulations, good housekeeping can reduce the classification from Division 1 to Division 2.
However, housekeeping should not be used as a primary method of dust control but should rather be used
to supplement control and elimination of dust at its source.
2.2.1.2.4 Guidelines in NFPA 499 may be used as an aid in applying judgement to determine the extent of
Division 1 and Division 2 areas for a Class II location. Since NFPA documents normally recommend what
are considered minimum criteria, considerable judgement may still be needed in the evaluation of a specific
situation.
Note: Paragraph A-3-1.2 of NFPA 499-1997 with dust layer thickness criteria based on a 24-hour
accumulation period should not be used. It could lead to underclassifying areas that may be hazardous.
2.3 Equipment and Processes
2.3.1 General
2.3.1.1 If available, Approved equipment should be recommended. When Approved equipment is not
available, equipment listed, labeled, or approved by another recognized testing laboratory is acceptable.
Note: FM Approvals can conduct testing to satisfy both the ‘‘Division’’ and ‘‘Zone’’ hazardous location
classification methods, and also has reciprocal interlaboratory testing agreements with other testing agencies
worldwide.

2.3.2 Specific Electrical Wiring and Equipment Requirements
2.3.2.1 Class I Hazardous Locations

2.3.2.1.1 In Class I or comparable hazardous locations per IEC or CENELEC standards (i.e., IEC 60079-10
or EN 60079-10), electrical equipment should be one of or a combination of the protected types as shown
in Table 3. See C.2.4 through C.2.9 for further explanation of the various protection concepts used with this
electrical equipment.
Table 3. Protected Types of Electrical Equipment for Class I Locations per the NEC or
Comparable Hazardous Locations per IEC or CENELEC Standards
Method of Protection
Protection Code Permitted Use Standard Principle
Increased Safety AEx e Class I, Zone 1, 2 FM 3619*(ISA S12.16.01) No arcs, sparks or hot
EEx e Zone 1, 2 EN 50119 surfaces
Ex e Zone 1, 2 IEC 79-7
Non-Incendive (NI) Class I, Division 2 FM 3611
Non-Sparking Ex nA Zone 2 IEC 79-15
Explosionproof (XP) Class I, Division 1, 2 FM 3615 Contain the explosion
Flameproof AEx d Class I, Zone 1, 2 FM 3618*(ISA S12.22.01) and quench the flame
EEx d Zone 1, 2 EN 50018
Ex d Zone 1, 2 IEC 79-1
Powder Filled AEx q Class I, Zone 1, 2 FM 3622*(ISA S12.25.01)
EEx q Zone 1, 2 EN 50017
Ex q Zone 1, 2 IEC 79-5
Enclosed Break Ex nC Zone 2 IEC 79-15
Intrinsic Safety (IS) Class I, Division 1, 2 FM 3610** Limit energy of sparks
AEx ia Class I, Zone 0,1, 2 FM 3610** and surface temperature
AEx ib Class I, Zone 1, 2 FM 3610**
EEx ia Zone 0, 1, 2 EN 50020/39
EEx ib Zone 1, 2 EN 50020/39
Ex ia Zone 0, 1, 2 IEC 79-11
Ex ib Zone 1, 2 IEC 79-11
Limited Energy Ex nA Zone 2 IEC 79-15
Pressurized Type X Class I, Division 1 FM 3620 Keep flammable gas out
Type Y Class I, Division 1 FM 3620
Type Z Class I, Division 2 FM 3620
EEx p Zone 1 EN 50016
Ex p Zone 1 IEC 79-2
Restricted Breathing Ex nR Zone 2 IEC 79-15
Encapsulation AEx m Class I, Zone 1, 2 FM 3614*(ISA S12.26.01)
EEx m Zone 1, 2 EN 50028
Ex m Zone 1, 2 IEC 79-18
Oil Immersion AEx o Class I, Zone 1, 2 FM 3621*(ISA S12.26.01)
EEx o Zone 1, 2 EN 50015
Ex o Zone 1, 2 IEC 79-15
*Also shall comply with ISA S12.0.01
**Based on ISA S12.2.01
Note: Where non-incendive electrical equipment is provided in Class I, Division 2 hazardous locations, a special enclosure is not needed,
just a general purpose enclosure.
2.3.2.1.2 Equipment approved and used in Class I hazardous locations also should be approved for the
specific group (A, B, C or D per NEC Article 500) or (IIC, IIB or IIA per NEC Article 505 or the corresponding
IEC or CENELEC standard) of the gas or vapor that will be present.
Note: Needed electrical equipment protective features are based on the degree or severity of hazard
exposure. Different flammable gases and vapors represent such a wide range of degree or severity of hazard
that further grouping (subdivision) is necessary to facilitate testing and approving/listing of appropriately
designed hazardous location electrical equipment. See Section C.3 for further explanation of group
classifications.

2.3.2.1.3 Heat producing equipment (i.e., motors and lighting fixtures but not equipment such as junction
boxes, conduit and electric wiring fittings) should be marked to show the class, group and operating
temperature. Temperature identification numbers (T codes) marked on the equipment should be in accordance
with Table 4 below. The surface temperature of the equipment (see Table 4) should not exceed the ignition
temperature of the specific gas or vapor to be encountered. Ignition temperatures for many gases and vapors
are provided in NFPA 497.
Table 4. T Codes (Temperature Identification Numbers)

Maximum NFPA (NEC Article 505)
Surface Temperature NFPA (NEC Article 500) IEC CENELEC
450°C (842°F) T1 T1
300°C (572°F) T2 T2
280°C (536°F) T2A
260°C (500°F) T2B
230°C (446°F) T2C
215°C (419°F) T2D
200°C (392°F) T3 T3
180°C (356°F) T3A
165°C (329°F) T3B
160°C (320°F) T3C
135°C (275°F) T4 T4
120°C (248°F) T4A
100°C (212°F) T5 T5
85°C (185°F) T6 T6
The ignition temperature for which existing equipment was approved in past years (prior to the establishment
of T codes in NFPA 70 — 1971) should be assumed to be as follows:
Group A, B, D: 280°C (536°F)
Group C: 180°C (356°F)
2.3.2.1.4 Where unclassified areas exist at elevations directly above a Division 1 or Zone 1 area, and ordinary
electrical equipment is located within that unclassified area, provisions should be made to ensure that failure
or foreseeable mechanical damage to that equipment would not allow parts or fragments hot enough to
cause ignition to fall into the Division 1 or Zone 1 area.
Example 1: Metal halide or mercury lamps, which are known to rupture in the event of a defect, should
be located within a fixture able to contain fragments of hot quartz or glass.
Example 2: Ordinary incandescent light bulbs, which are easily broken by impact, should be enclosed within
substantial guards or globes.
2.3.2.1.5 Electrical equipment and wiring recommended for locations containing flammable vapors or gases
should be provided per Table 5. Refer to Article 501 of the NEC or IEC 60079-14 Ed. 2.0: Electrical apparatus
for explosive gas atmospheres — Part 14: Electrical installations in hazardous areas (other than mines),
for additional requirements.

Table 5. Equipment Recommended for Locations Containing Flammable Gases or Vapors (Class I)*
Division 1 Division 2
Wiring Threaded rigid metal conduit or Type MI Threaded rigid metal conduit, threaded
cable. Explosionproof boxes and fittings. steel intermediate metal conduit, enclosed
Use seals to prevent passage of gases, gasketed wireways, enclosed gasketed
vapors, or flames through conduit from one busways, or Type MI, MC, PLTC, MV, TC,
portion of electrical installation to another. or SNM cable. No seals required except
Threaded joints must have at least 5 where explosionproof equipment is
threads engaged. Avoid tensile stress at necessary and conduit leaves hazardous
termination fittings. Use approved flexible area. Wiring, which under normal conditions
fittings for Class I locations. cannot release sufficient energy to ignite a
specific hazardous atmospheric mixture,
can be accepted using any of the methods
suitable for wiring in ordinary locations.
Switches, circuit Install in an enclosure approved as a Same as Division 1, unless general
breakers, and motor complete assembly for Class I, Division 1 enclosures are provided and the
controllers locations. (Enclosures approved for Class I, interruption of current occurs in hermetically
Division 1 locations include explosionproof sealed chambers, the contacts are oil-
and purged and pressurized enclosures.) immersed, or interruption occurs in an
approved explosionproof chamber. (General-
purpose enclosures are acceptable for
isolating or disconnecting switches without
fuses and not intended to interrupt current.)
Fuses Install in an enclosure approved as a Install in an enclosure approved for Class I,
complete assembly for Class I, Division 1 Division 1 locations, for fuses protecting
locations. (Enclosures approved for Class I, motors, appliances, and portable lamps.
Division 1 locations include explosionproof General purpose enclosures are acceptable
and purged and pressurized enclosures.) for these fuses if the operating element of
the fuse is oil-immersed or in hermetically
sealed chamber. (General-purpose
enclosures are acceptable for fuses on
circuits to fixed lamps.)
Receptacles and Polarized type approved for Class I Same as Division 1.
attachment plugs locations, having provision for connection to
grounding conductor of flexible cord.
Motors and generators Approved for Class I locations, or totally Enclosure approved for Class I locations for
enclosed type supplied with positive rotating electrical machines employing
pressure ventilation from a source of clean sliding contacts, centrifugal or other
air, or totally enclosed inert gas filled type switches or integral resistors, unless such
supplied with a source of inert gas to contacts, switches, and resistors have
pressurize the enclosure, or a type enclosures approved for Class I, Division 1
designed to be submerged in a liquid that is locations. Open polyphase squirrel-cage
flammable only when vaporized and mixed induction motors without brushes or
with air. The different types should be switches are acceptable. (Enclosed
arranged to automatically de-energize the polyphase squirrel-cage induction motors
equipment when the supply of liquid, gas or are preferable for new installations.)
vapor fails.

Lighting fixtures Fixed and portable units approved as Fixed enclosed gasketed globes or other
complete assembly for Class I, Division 1 effective protective means where
locations. Fixtures should have guards (a) flammable liquids are in the open, or
surrounding the globes or be located so as (b) sparks or hot metal from lamps or
not to be subject to physical damage. fixtures might ignite local concentrations of
Pendant fixtures should be suspended by flammable vapors or gases. Use lamps of a
threaded rigid metal conduit or threaded size or type that do not reach surface
steel intermediate conduit stems or by other temperatures in excess of 80 of the ignition
approved means. Supports should be temperature (°C) of the gas or vapor
approved for Class I locations. involved; or use fixed fixtures approved as
complete assembly for Class I, Division 1
locations. Other fixed lighting units may be
ordinary open type without switches,
starters, or control equipment.
Fixtures for fixed lighting should have
guards or be located so as not to be
subject to physical damage.
Portable lamps to be approved as complete
assembly for Class I, Division 1 locations.
Pendent fixtures per Division 1.
Transformers and Install units containing either flammable or Install according to rules of sections 450-21
capacitors nonflammable liquid in approved vaults to 450-27 of NEC for nonhazardous
having no openings to hazardous areas.** locations.
Use units approved for Class I locations for
those that do not contain a liquid that will
burn.
Meters, relays, and Provide enclosure approved for Class I, Equipment containing make-and-break
instruments Division 1 locations, or intrinsically contacts should have enclosures approved
safe equipment. (Enclosures approved for for Class I, Division 1 locations. General
Class I, Division 1 locations include purpose enclosures are acceptable if current-
explosionproof and purged and pressurized interrupting contacts are (a) oil-immersed,
enclosures.) or (b) hermetically sealed, or (c) in circuits
that under normal conditions do not release
sufficient energy to ignite a specific
hazardous atmospheric mixture, i.e., are
non-incendive.
Equipment such as transformer windings,
solenoids, and other windings that do not
contain sliding or make-and-break contacts
is acceptable in general purpose
enclosures.
* Wherever possible, locate electrical equipment outside of hazardous areas. More specific details are given in Article 501 of the NEC.
Also see Article 501 of the NEC for details on equipment not covered in Table 5.
** Units containing flammable liquid must have ample ventilation, vent openings or ducts leading to a safe location outside the building
and vents and ducts of sufficient area for explosion relief. Ducts within buildings shall be of reinforced concrete construction.
2.3.2.2 Class II Hazardous Locations

2.3.2.2.1 In Class II hazardous locations electrical equipment should be of one or a combination of the
following types:
a) dust-ignitionproof (See C.2.8)
b) intrinsically safe (See C.2.5)
c) non-incendive (See C.2.6)
d) pressurized (See C.2.4 and C.2.9)
2.3.2.2.2 Equipment approved for Class II hazardous locations also should be approved for the specific group
(E, F or G) of dust that will be present.
Note: There are no comparable dust groups in IEC or CENELEC standards.

2.3.2.2.3 The surface temperature markings in Table 4 should be less than the ignition temperature of the
specific dust encountered. Ignition temperatures of many common dusts are provided in NFPA 499. The
ignition temperature for which existing equipment was approved in past years (prior to the establishment
of T codes in NFPA 70-1971) should be assumed to be as shown in Table 6.
Table 6. Surface Temperature Limits

Equipment Not Subject Equipment That May Be Overloaded
To Overloading Normal Operation Abnormal Operation
Class II Group °F °C °F °C °F °C
E 392 200 392 200 392 200
F 392 200 302 150 392 200
G 329 165 248 120 329 165
2.3.2.2.4 Electrical equipment and wiring recommended for locations containing combustible dusts should
be provided per Table 7. Refer to Article 502 of the NEC or IEC 61241-1-1 Ed. 1.0: Electrical apparatus for
use in the presence of combustible dust — Part 1: Electrical apparatus protected by enclosures — Section 1:
Specifications for apparatus, and IEC 61241-1-2 Ed. 1.0: Electrical apparatus for use in the presence of
combustible dust — Part 1: Electrical apparatus protected by enclosures — Section 2: Selection, installation
and maintenance, for additional requirements.
Table 7. Equipment Recommended for Locations Containing Combustible Dusts (Class II)*
Wiring Threaded rigid metal conduit, threaded Rigid metal conduit, electric metallic tubing,
steel intermediate metal conduit or Type MI intermediate metal conduit, dust-tight
cable with termination fittings. Use units wireways or Type MI, MC, SNM cable with
approved for Class II locations for boxes or approved termination fittings, or Type MC,
fittings containing taps, joints, or terminal PLTC or TC cable in ventilated channel
connections, or in locations where dusts are type cable trays in a single layer with a
combustible and electrically conducting. space not less than the larger cable
Seals are needed in conduit connecting dust- diameter between the two adjacent cables.
ignitionproof and non-dust-ignitionproof Same as Division 1 for sealing.
enclosures.
Switches, circuit breakers, Install in an enclosure approved as a Install in a tight metal enclosure with close
and motor controllers complete assembly for Class II, Division 1 fitting cover to minimize entrance of dust,
locations for devices that normally interrupt and to prevent escape of sparks or burning
current or where dusts are combustible and material.
electrically conducting. (Enclosures
approved for Class II, Division 1 locations
include dust-ignitionproof and purged and
pressurized enclosures.) Isolating or
disconnecting switches without fuses and
not subject to the above conditions should
have tight metal enclosures and covers to
minimize entrance of dust, and to prevent
escape of sparks or burning material.
Locations having metal dusts should have
approved enclosures.
Fuses Same as for other spark-producing devices Same as for other spark-producing devices
above. above.
Receptacles and Polarized type approved for Class II Polarized type with grounding connection
attachment plugs locations, having provision for connection to and so designed that connection to the
grounding conductor of flexible cord. supply circuit cannot be made or broken
while live parts are exposed.

Motors and generators Approved for Class II locations or totally Totally enclosed nonventilated, totally
enclosed pipe ventilated meeting any enclosed fan cooled, dust-ignitionproof or
temperature limitations. totally enclosed pipe ventilated, for which
maximum surface temperature does not
exceed the ignition temperature of the
specific dust (see Table 4) and shall have
no external openings. Where moderate
accumulations of nonconducting
nonabrasive dust occur and equipment is
accessible for cleaning, it is acceptable to
use (a) self-cleaning textile-type squirrel-
cage motors, or (b) standard open motors
without sliding contacts, switches, or
resistance devices or (c) with contacts,
switches or resistance devices, enclosed in
dust tight housings.
Lighting fixtures Fixed and portable units approved as For fixed lights, provide enclosures to
complete assembly for Class II, Division 1 minimize dust deposits, prevent escape of
locations. Provide guards or locate to sparks or burning material, and maintain
prevent physical damage. Pendant fixtures exposed surface temperature less than the
should be suspended by threaded rigid ignition temperature of the specific dust.
metal conduit or intermediate metal conduit Provide guards or locate to prevent physical
stems or by other approved means. damage. Portable units approved for Class
Supports should be approved for Class II II, Division 1 locations. Pendent fixtures as
locations. in Division 1.
*Capacitors and Install units containing flammable liquid in Install units containing flammable liquid in
transformers approved vaults. Any openings to approved vaults. Install dry-type
hazardous areas should be protected by transformers in vaults or tight metal
double, tight-fitting, self-closing fire doors. housings without openings, and do not
Ventilating and pressure-relief openings operate at voltages above 600 volts. Install
should communicate only to outside air. askarel transformers rated in excess of
Install units that do not contain a liquid that 25 kVA in accordance with rules for
will burn in approved vaults, or use those nonhazardous locations. Locate these
approved as a complete assembly for Class transformers so that there is an air space of
II locations. Transformers/capacitors may not less than 6 in. (15.2 cm) between the
not be installed in locations containing transformer cases and any adjacent
metal dusts combustible material. Transformers should
be provided with pressure-relief vents and
have means of absorbing any gases inside
the case or venting gases to outside the
building.
Meters, relays, and Enclosure approved for Class II, Division 1 Tight metal enclosures and covers to
instruments locations, or intrinsically safe equipment. minimize entrance of dust, and prevent
(Enclosures approved for Class II, Division escape of sparks and burning material.
1 locations include dust-ignitionproof and
purged and pressurized enclosures.)
* Wherever possible, locate electrical equipment outside of hazardous areas. More specific details are given in Article 502 of the NEC.
Also see Article 502 of the NEC for details on equipment not covered in Table 7.
2.3.3 Purged and Pressurized Enclosures for Electrical Equipment in Class I and Class II Hazardous
(Classified) Locations
2.3.3.1 General Requirements for Pressurized Enclosures

NOTE: The following design requirements for pressurized enclosures are not all inclusive. The
recommendations in Section 2.3.3 present only those basic requirements that are expected to have the
greatest impact on loss history. For exceptions and additions see NFPA 496, Purged and Pressurized
Enclosures for Electrical Equipment. The 1998 Edition of NFPA 496 also recognizes the ‘‘zone’’ approach for
Class I hazardous (classified) locations. Therefore, Zone 1 and Zone 2 locations may be equated to Division
1 and Division 2 locations, respectively within Section 2.3.3 for Class I locations only.

2.3.3.1.1 Pressurized enclosures may be used to locate electrical equipment in hazardous locations for which
the equipment would otherwise be unsuitable. The three types of pressurization generally used for electrical
equipment enclosures are Types X, Y, and Z. Type X pressurizing should be used to reduce the classification
inside the protected enclosure from Division 1 to nonclassified. Type Y pressurizing should be used to reduce
the classification within the protected enclosure from Division 1 to Division 2. Type Z pressurizing should
be used to reduce the classification inside the protected enclosure from Division 2 to nonclassified.
2.3.3.1.2 During operation of the protected equipment, the protected enclosure should be maintained at a
positive pressure of not less than 25 Pa (0.1 in. water) above the surrounding atmosphere.
2.3.3.1.3 An alarm should be provided to indicate the loss of the protective gas supply. However, an alarm
on the supply is unnecessary if individual alarms are provided for each protected enclosure, or if Type X
pressurization is used. Alarms on either the gas supply or protected enclosures should sound at a constantly
attended location.
2.3.3.1.4 Acceptable protective gases include air of normal instrument quality, nitrogen or other
nonflammable gases. Compressed air is acceptable if the compressor intake is located in a nonclassified
location.
2.3.3.1.5 The protective gas should be discharged from the enclosure to a nonclassified location.
2.3.3.1.6 Temperatures or T codes should be marked on the enclosures, and should indicate the highest
of the following: a) the hottest external surface temperature, b) the hottest internal component surface, or
c) the temperature of the protective gas leaving the enclosure. The T code marking is not necessary if the
hottest temperatures cannot exceed 100°C (212°F).
2.3.3.1.7 A permanent label should be mounted on the purged and pressurized enclosure and should state
that the enclosure should not be opened unless the area is known to be nonhazardous or unless power has
been removed from devices in the enclosure.
2.3.3.1.8 The area classification for the enclosure and pressurization type should be marked on the
enclosure.
2.3.3.1.9 Type Z Pressurization
a) An alarm or indicator should be provided to detect the loss of positive pressure in individually protected
enclosures. The protected equipment does not need to be de-energized.
b) If provided, an indicator should be located for convenient viewing and should indicate pressure or flow.
2.3.3.1.10 Type Y Pressurization
a) The features indicated for Type Z pressurizing systems should be provided.
b) Equipment inside the enclosure should be Approved for Division 2 locations.
c) Where the flow of protective gas provides needed equipment cooling as well as pressurization, the
equipment should be interlocked to de-energize when the flow of gas is stopped.
2.3.3.1.11 Type X Pressurization
a) Circuits should be de-energized automatically using a flow or pressure actuated cutoff switch upon
failure of the protective gas supply.
b) Equipment that could be overloaded (e.g., motors, transformers) should be provided with temperature
measurement devices, and should be interlocked to automatically de-energize upon detection of any
increase in temperature beyond the equipment design limits. Alternatively, the flow rate of protective gas
should provide sufficient cooling even during overload conditions.
2.3.3.2 Specific Requirements for Pressurized Enclosures in Class I Locations

2.3.3.2.1 The enclosure should be purged if it has been opened or if the protective gas supply has failed
to maintain the required positive pressure.
2.3.3.2.2 Pressurized equipment should not be energized until at least four enclosure volumes of protected
gas (ten volumes for motors) have passed through the enclosure while maintaining an internal pressure of
at least 25 Pa (0.1 in. water). For Type X pressurization, a timing device should be used to prevent energizing
of electrical equipment prior to the required purging.

2.3.3.3 Specific Requirements for Pressurized Enclosures in Class II Locations

2.3.3.3.1 Accumulated combustible dust should be removed from the enclosure before pressurization.
2.3.3.3.2 The pressure required inside the protected enclosure should be increased to 125 Pa (0.5 in.
water)(rather than the normally required 25 Pa (0.1 in. water) if the particle density of the dust is 130 lb/ft3
(2083 kg/m3) or greater.
2.3.3.3.3 Maximum surface temperatures should not exceed those stated in 2.3.2.2.3 if the ignition
temperature of the dust is unknown.
2.3.3.3.4 For Type X pressurization a cutoff switch as in 2.3.3.1.11 is not required if an alarm is provided
at a constantly attended location, and the enclosure is tightly sealed to prevent the entrance of dust.
2.3.3.4 FM Approved vs Non Approved Equipment
2.3.3.4.1 Equipment that is Approved or listed as Purged and Pressurized will be so labeled, and can be
accepted for use within the area Class and Divisions or Zones as marked. Equipment that is not Approved
or listed may be accepted if it meets the requirements detailed in Section 2.3.3. Additional detailed
requirements of NFPA 496 should also be met where Code compliance is sought.
2.4 Operation and Maintenance

2.4.1 Maintain electrical equipment in accordance with the manufacturer’s guidelines and NFPA 70B,
Recommended Practice for Electrical Equipment Maintenance. Care should be taken during maintenance
of hazardous (classified) location electrical equipment to ensure the continued integrity of protection for such
equipment.
3.0 SUPPORT FOR RECOMMENDATIONS
3.1 General
Following the recommendations in this loss prevention data sheet is needed to minimize the potential for
electrical ignition of flammable gases, flamable vapors and combustible dusts within areas or equipment
where they are handled.
4.0 REFERENCES
4.1 FM Global
Data Sheet 7-1, Fire Protection for Textile Mills.
Data Sheet 7-9, Dip Tanks, Flow Coaters and Roll Coaters.
Data Sheet 7-13, Mechanical Refrigeration.
Data Sheet 7-27, Spray Application of Flammable and Combustible Materials.
Data Sheet 7-30N, Solvent Extraction Plants.
Data Sheet 7-32, Flammable Liquid Operations.
Data Sheet 7-55/12-28, Liquefied Petroleum Gas.
4.2 NFPA Standards

NFPA 70, National Electrical Code.
NFPA 70B, Recommended Practice for Electrical Equipment Maintenance.
NFPA 496, Purged and Pressurized Enclosures for Electrical Equipment.
NFPA 497, Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors and of
Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas.
NFPA 499, Recommended Practice for the Classification of Combustible Dusts and of Hazardous (Classified)
Locations for Electrical Installations in Chemical Process Areas.
4.3 Others
CSA Standard C22.1-98, Canadian Electrical Code, Part 1.

IEC 60079-10:1995 or EN 60079-10:1996, Electrical apparatus for explosive gas atmospheres — Part 10:
Classification of hazardous areas.
IEC 60079-14 Ed. 2.0: Electrical apparatus for explosive gas atmospheres — Part 14: Electrical installations
in hazardous areas (other than mines).
IEC 61241-1-1 Ed. 1.0: Electrical apparatus for use in the presence of combustible dust — Part 1: Electrical
apparatus protected by enclosures — Section 1: Specifications for apparatus.
IEC 61241-1-2 Ed. 1.0: Electrical apparatus for use in the presence of combustible dust — Part 1: Electrical
apparatus protected by enclosures — Section 2: Selection, installation and maintenance.
IEC 61241-3:1997, Electrical apparatus for use in the presence of combustible dust — Part 3: Classification
of areas where combustible dusts are or may be present.
LeBlanc, J. A. and Lawrence, W. G., ‘‘The Three-Zone Classification System and the National Electric Code,’’
Paper 5b, presented at AIChE 34th Annual Loss Prevention Symposium, Atlanta (March 5–9, 2000).
APPENDIX A GLOSSARY OF TERMS

Approved: references to ‘‘Approved’’ in this data sheet means the product and services have satisfied the
criteria for FM Approval. Refer to the Approval Guide, a publication of FM Approvals, for a complete listing of
products and services that are FM Approved.
See Appendix C, Section C.2 for an explanation of some common hazardous location electrical equipment
terms, including the various protected types of electrical equipment.
APPENDIX B DOCUMENT REVISION HISTORY

September 2006. Added information on the acceptability of portable electronic products to Appendix C.
January 2002. Added reference paper under Appendix E entitled ‘‘The Three-Zone Classification System
and the National Electric Code’’ for further guidance in the application of the ‘‘Zone’’ classification method
as covered by Article 505 of NFPA 70, National Electric Code.
September 2000. This revision of the document has been reorganized to provide a consistent format.
APPENDIX C SUPPLEMENTARY INFORMATION
C.1 General
The NEC divides hazardous locations into three ‘‘classes’’ according to the nature of the hazard: Class I,
Class II, and Class III. The locations in each of these classes are further classified by ‘‘divisions’’ (or ‘‘zones’’
for Class I locations only) according to the degree of hazard. Class I and II locations and their divisions (or
zones for Class I locations) are described in Section C.2 of this appendix.
It is sometimes possible to avoid the use of special hazardous location electrical equipment and wiring by
locating the equipment and wiring outside the hazardous location. For example, lights may be located outside
a room, illuminating the inside through transparent panels. Motors may be located outside hazardous
locations with properly sealed shafts extending into the hazardous location to drive mechanical equipment.
Power equipment and control instruments may be located in remote, nonhazardous locations or in
pressurized rooms that are suitable for general purpose equipment.
Considerable judgement is required to properly classify an area as a hazardous location. Unnecessarily
expensive installations can be avoided by not over-classifying an area or by using expensive, explosionproof
equipment that is sometimes rated for a higher classification.
C.2 Explanatory Material

The basic descriptions of Class I and II hazardous locations, nonclassified locations and pressurized
enclosures for Class I and II locations are contained in the NEC, Articles 500 and 505, as well as NFPA Nos.
496, 497 and 499.

C.2.1 Class I Hazardous Locations

Class I Locations. Class I locations are those in which volatile flammable gases or vapors are or may be
present in air in quantities sufficient to produce ignitible mixtures. These locations often include processes
where volatile flammable liquids are used. Per recent consultations with NEC specialists, Class I locations also
include those where ignitible mists are normally present where the liquid has a flash point above 100°F (38°C)
and is not heated above its flash point.
Volatile Flammable Liquid. Volatile flammable liquids are defined as liquids that have (a) a closed cup flash
point below 100°F (38°C) or (b) a closed cup flash point of 100°F (38°C) and above if heated higher than
their flash point.
The design of electrical equipment for Division 1 locations is based on a flammable atmosphere being
continuously present, as this is the worst case situation.
Examples of Class I, Zone 0 locations include areas inside vented tanks or vessels containing volatile
flammable liquids; areas inside inadequately ventilated spraying or coating enclosures where volatile
flammable liquids are used; the area between the inner and outer roof sections of a floating roof tank
containing volatile flammable liquids; areas inside open vessels, tanks and pits containing volatile flammable
liquids; the interior of an exhaust duct that is used to vent ignitable concentrations of gases or vapors; and
areas inside inadequately ventilated enclosures containing normally venting instruments utilizing or analyzing
flammable liquids and venting to the inside of the enclosures.
Examples of Class I, Division 1 or Zone 1 locations include areas where volatile flammable liquids or liquefied
flammable gases are transferred from one container to another; interiors of spray booths and areas in the
vicinity of spraying and painting operations where volatile flammable solvents are used; locations containing
open tanks or vats of volatile flammable liquids; drying rooms or compartments for the evaporation of
flammable solvents; locations containing fat and oil extraction equipment using volatile flammable solvents;
portions of cleaning and dyeing plants where flammable liquids are used; gas generator rooms and other
portions of gas manufacturing plants where flammable gas may escape; inadequately ventilated pump rooms
for flammable gas or for volatile flammable liquids; the interiors of refrigerators and freezers in which volatile
flammable materials are stored in open, lightly stoppered, or easily ruptured containers; and all other
locations where ignitible concentrations of flammable vapors or gases are likely to occur in the course of
normal operations but are not classified Zone 0.
Electrical installations in Class I, Division 1 or Zone 1 locations are designed so that normal operation or
failure of any part of the electrical system will not release flame, sparks, or hot gases, nor will it result in surface
temperatures high enough to ignite the surrounding atmosphere.
Protection systems for Division 2 or Zone 2 locations are not as stringent as they are for Division 1 or Zone 0
and Zone 1 locations since flammable gases and vapors are not present under normal conditions, and are
likely to be present only for relatively short periods under abnormal conditions.
Installations for Class I, Division 2 or Zone 2 locations are designed and arranged so that normal operation
of the electrical system does not provide a source of ignition. Protection against ignition during electrical
breakdown is not provided. However, electrical breakdowns are sufficiently rare that the likelihood of one
occurring simultaneously with accidental release of an ignitible mixture is extremely remote. Arcing and
sparking devices are permitted only if suitably enclosed or if the sparks are of insufficient energy to ignite the
mixture.
Adequate mechanical ventilation can be used to reclassify a location from Division 1 to Division 2 or Zone
1 to Zone 2 or in some instances even result in reclassification as nonhazardous and avoid costly Division 2
or Zone 2 wiring. Typical examples where adequate ventilation would not reduce the classification level
include: within 3 ft (0.9 m) of the fill opening of an indoor flammable liquid drum, locations under and adjacent
to open kettles, mixers or dip tanks (and their drainboards) containing volatile flammable liquids, the
immediate vicinity of continuous cleaning operations where exposed flammable liquids are used, the
immediate vicinity of open filter presses processing volatile flammable liquids and in the immediate vicinity
of normally closed equipment that is frequently opened and that contains volatile flammable liquids or
flammable vapors or gases.

C.2.2 Class II Hazardous Locations

Class II Locations. Class II locations are locations that are hazardous because combustible dusts are or
may be present.
Examples of typical Class II, Division 1 locations include the working areas of grain handling and storage
plants; rooms containing such equipment as grinders, pulverizers, open conveyors, or similar dust producing
machinery in plants processing grain, malt, starch, sugar, wood, flour, or similar materials; starch-handling
areas in candy plants; coal pulverizing plants (except where the pulverizing equipment is essentially dust
tight); areas where metal dusts and powders are produced, handled, or stored (except in tight containers);
and other similar locations where combustible dust may, under normal operating conditions, be present in the
air in quantities sufficient to produce ignitible mixtures.
Dusts containing magnesium or aluminum are particularly hazardous and extreme caution is necessary to
avoid ignition or explosion.
Examples of typical Class II, Division 2 locations include those containing only closed conveyors, closed
bins, or machines from which appreciable quantities of dust would escape under abnormal operating
conditions; rooms adjacent to Class II, Division 1 locations into which ignitible concentrations of suspended
dust might be communicated only under abnormal operating conditions; or rooms where ignitible
concentrations of suspended dust are normally prevented by effective dust control equipment.
Electrical installations in Class II, Division 1 locations are designed and enclosed in a manner that will exclude
ignitible amounts of dusts and will not permit arcs, sparks, or heat generated or liberated inside the
enclosures to cause ignition of exterior dust accumulations on the enclosure or of atmospheric dust
suspensions in the vicinity of the enclosure.
Electrical installations in Class II, Division 2 locations may be designed with dust-tight enclosures or other
equipment enclosures as specified in Article 502 of the NEC.
C.2.3 Nonclassified Locations

Experience has shown that the release of ignitible mixtures or dust suspensions from some operations and
apparatus is so infrequent that area classification is not necessary. For example, it usually is not necessary
to classify the following locations where combustible mixtures or ground up solids are processed, stored or
handled:
a) Locations that are adequately ventilated, where combustible materials are contained within suitable,
well maintained, closed piping systems.
b) Locations that are not adequately ventilated but where piping systems are without valves, fittings,
flanges, and similar accessories that may be prone to leaks.
c) Locations where combustible dusts are stored in sealed containers (bags, drums, fiber packs)are
palletized or racked.
d) Locations where combustible dusts are transported in well maintained closed piping systems.
e) Locations where palletized materials with minimal dust are handled or used.
f) Locations where mechanical dust collection systems on equipment prevent visual dust clouds and layer
accumulations that make surface colors indiscernible, and where appreciable quantities of dust are not
likely to escape under abnormal operating conditions.
g) Locations where excellent housekeeping is maintained and there are no visual dust suspensions or
layer accumulations that make surface colors indiscernible, and where appreciable quantities of dust are
not likely to escape under abnormal operating conditions.
The area directly adjacent to a normally present and unavoidable ignition source also is considered to be a
nonclassified location. Examples include areas adjacent to: fuel-fired equipment burners; hot exposed
surfaces that normally are above the autoignition temperature of gases, vapors or dusts that may be released;
and gas turbines. The use of classified area electrical equipment next to obvious ignition sources is
unwarranted due to the fact that the use of the special electrical equipment is not likely to significantly reduce
the probability of ignition of an accidental release of combustible material. It is not possible to provide fixed
guidelines regarding how far away from these ignition sources hazardous location electrical equipment

should be used again. Factors to consider in exercising judgment include the magnitude and location of
potential material releases or accumulations, as well as the potential distances that the released material
may drift
C.2.4 Purged and Pressurized Enclosures as covered by NFPA 496

Note: The 1998 Edition of NFPA 496 equates Class I, Zone 1 and Zone 2 locations to Class I, Division 1
and Division 2 locations, respectively as referenced below within this section.
C.2.4.1 Terminology
Purging: the process of supplying an enclosure with a protective gas at a sufficient flow and positive pressure
to reduce the concentration of any flammable gas or vapor initially present to an acceptably safe level.
Pressurization: the process of supplying an enclosure with a protective gas with or without continuous flow
at sufficient pressure to prevent the entrance of a flammable gas or vapor, a combustible dust or an ignitible
fiber.
Protective Gas: the gas used to maintain pressurization or to dilute a flammable gas or vapor.
Protective Gas Supply: the compressor, blower, or compressed gas container that provides the protective
gas at a positive pressure. The supply includes inlet (suction) pipes or ducts, pressure regulators, outlet pipes
or ducts, and any supply valves not adjacent to the pressurized enclosure.
C.2.4.2 Purged and Pressurized Enclosures for Class I Locations

Type X Pressurization reduces the classification within an enclosure from Division 1 to nonhazardous.
Because the probability of a hazardous atmosphere external to the enclosure is high and the enclosure
normally contains a source of ignition, it is essential that any interruption of the purging results in de-energizing
of the equipment. It is essential that the enclosure also be tight enough to prevent escape of molten metal
particles or sparks.
Type Y Pressurization reduces the classification within an enclosure from Division 1 to Division 2. Equipment
and devices within the enclosure must be suitable for Division 2. This requires that the enclosure not normally
contain an ignition source. Thus, a hazard is created within the enclosure only upon simultaneous failure
of the purge system and of the equipment within the enclosure. Due to the very low probability of this
occurring, it is not considered essential to de-energize the equipment upon the failure of the pressurization
system.
Type Z Pressurization reduces the classification within an enclosure from Division 2 to nonhazardous. With
Type Z Pressurization, a hazard is created only if the purge system fails at the same time that the normally
nonhazardous area becomes hazardous. Due to the low probability of this occurring, it is not considered
essential to de-energize the equipment upon failure of the pressurization system.
C.2.4.3 Purged and Pressurized Enclosures for Class II Locations

A hazard is created within an enclosure only after the pressure has failed and enough dust to be explosive
penetrates into the enclosure. This takes an appreciable length of time with any normally tight enclosure.
Because of this, it is not always considered essential to de-energize the equipment automatically upon failure
of the pressurization. It is necessary only to provide an adequate warning so that operations will not continue
indefinitely without pressurization. It is essential that the enclosure be tight enough to prevent escape of
sparks or burning material.
C.2.5 Intrinsically Safe Electrical Equipment

Intrinsically safe (‘‘IS’’ per NEC Article 500 or ‘‘ia’’ for Zones 0, 1 and 2 or ‘‘ib’’ for Zones 1 and 2 per NEC
Article 505 — see Table 3) equipment and wiring are designed to be incapable of releasing sufficient electrical
or thermal energy under normal or abnormal conditions to ignite a specific hazardous atmospheric mixture
in its most easily ignited concentration. Intrinsically safe apparatus is suitable for use in Class I, Division 1
and/or Class II, Division 1 hazardous locations, depending on the type of environment for which it has been
tested and Approved (listed).

The NEC and other corresponding IEC and CENELEC standards recognize intrinsically safe electrical
equipment and its wiring. The intrinsically safe apparatus is safe for use in the specified atmosphere without
the special enclosures or physical protection that would otherwise be needed.
Industrial applications of intrinsically safe electric circuits are increasing considerably. There is a greater use
of intrinsic safety to supplement or substitute for the other forms of protection in hazardous locations. Overall,
the principal of intrinsically safe equipment and circuits can be considered for any equipment that operates
at very low voltages and very low amperages. Intrinsically safe equipment is thus ideal for process monitoring
or controlling applications in chemical plants and petroleum refineries.
The ability of an electrical circuit or equipment to produce ignition is determined by the energy available and
the manner in which such energy is released. The energy may be released by arcing (a spark), by high
temperature, or by a combination of arcing and temperature. The energy released by an arc or spark discharge
can be by: a) the discharge of a capacitive circuit, b) the interruption of current in an inductive circuit, c) the
make-and-break of a resistive circuit, or d) a combination of these three mechanisms.
FM Global Research and other recognized laboratories examine electrical devices to determine, by analysis
and/or actual tests, the ignition capability of the particular equipment. The laboratories determine whether
or not the device is intrinsically safe for a specific hazardous location. Electrical equipment approved as
intrinsically safe is listed in the Approval Guide.
C.2.6 Non-Incendive Electrical Equipment

Non-incendive ‘‘(NI)’’ equipment and wiring are incapable of releasing sufficient electrical or thermal energy,
during normal operating conditions, to ignite a specific hazardous atmosphere mixture. Such non-incendive
equipment is safe for use in Class I, Division 2 or Class II, Division 2 hazardous locations, depending on
the type of environment for which it has been tested and approved (listed). A special enclosure or other
physical safeguard for the equipment is not needed.
Electrical equipment approved as non-incendive is listed in the Approval Guide.
C.2.7 Explosionproof Equipment

The term explosionproof ‘‘(XP)’’ means that the device has an enclosure that is capable of withstanding an
internal explosion of a specified gas or vapor without igniting a similar external mixture. In addition, the
maximum external surface temperatures are below the ignition temperature of the materials to which the
enclosure may be exposed. Explosionproof equipment is suitable for Class I, Division 1 locations.
C.2.8 Dust-ignitionproof Equipment

The term dust-ignitionproof ‘‘(DIP)’’ means that the device has an enclosure that will exclude ignitible amounts
of dust. In addition, the enclosure will not permit arcs, sparks, or heat generated inside the enclosure to ignite
exterior accumulations of dust. This is the type of design most frequently used for Class II, Division 1
equipment.
C.2.9 Other Protected Types of Electrical Equipment

Flameproof ‘‘d’’ is a type of protection of electrical equipment in which the enclosure will withstand an internal
explosion of a flammable mixture that has penetrated into the interior, without suffering damage and without
causing ignition, through any joints or structural openings in the enclosure, of an external explosive mixture
consisting of one or more of the gases or vapors for which it is designed.
Pressurized ‘‘p’’ is a type of protection of electrical equipment that guards against the ingress of the external
atmosphere, which may be explosive, into an enclosure by maintaining a protective gas therein at a pressure
above that of the external atmosphere.
Type of Protection ‘‘n’’ is a type of protection applied to electrical equipment such that, in normal operation,
the electrical equipment is not capable of igniting a surrounding explosive gas atmosphere and a fault
capable of causing ignition is not likely to occur. Type of protection ‘‘n’’ is further subdivided into nA
(non-sparking equipment), nC (sparking equipment in which the contacts are suitably protected other than
by restricted breathing enclosure) and nR (sparking equipment that has restricted breathing enclosure).

Oil Immersion ‘‘o’’ is a type of protection in which the electrical equipment or parts of the electrical equipment
are immersed in a protective liquid in such a way that an explosive atmosphere that may be above the liquid
or outside the enclosure cannot be ignited.
Increased Safety ‘‘e’’ is a type of protection applied to electrical equipment that does not produce arcs or
sparks in normal service and under specified abnormal conditions, in which additional measures are applied
so as to give increased security against the possibility of excessive temperatures and of the occurrence of
arcs and sparks.
Encapsulation ‘‘m’’ is a type of protection in which the parts that could ignite an explosive atmosphere by
either sparking or heating are enclosed in a compound in such a way that this explosive atmosphere cannot
be ignited.
Powder Filling ‘‘q’’ is a type of protection in which the parts capable of igniting an explosive atmosphere are
fixed in position and completely surrounded by filling material (glass or quartz powder) to prevent the ignition
of an external explosive atmosphere.
C.3 Group Classification

The atmosphere created by flammable vapors, gases or dusts makes them more or less hazardous around
specific electrical equipment. Atmospheric mixtures using the ‘‘Division’’ hazardous area classification method
per NEC Article 500 are further classified into seven groups (A through G) for purposes of testing and
approving pieces of electrical equipment for their suitability for various atmospheres.
Groups A, B, C and D per the ‘‘Division’’ approach or corresponding Groups IIC, IIB and IIA per the ‘‘Zone’’
approach consist of flammable gases or vapors as further explained in Table 8. They are classified according
to either (1) their ability to propagate flame through a flanged joint (MESG value — maximum experimental
safe gap value), or (2) their minimum igniting current (MIC) ratio, or both. See C.6.1 for further clarification.
Groups E through G consist of combustible dusts and are further explained in Table 9. They are classified
according to (1) their ability to penetrate joints, (2) their blanketing effect, (3) their ignition temperatures, and
(4) their electrical conductivity.
Refer to either NFPA 497 (gases and vapors) or NFPA 499 (dusts) for a comprehensive list of materials
including their group classification.
Table 8. Group Classifications for Flammable Gas and Vapor Atmospheres

Typical Flammable Gas NEC Article 505
or Vapor Atmosphere NEC Article 500 or IEC/CENELEC
Acetylene Group A Group IIC MESG value ≤ 0.50 mm or MIC
Hydrogen Group B MESG value ≤ 0.45 mm or MIC ratio ≤ 0.45
ratio ≤ 0.40
Ethylene Group C MESG value > 0.45 mm Group IIB MESG value > 0.50 mm and
and ≤ 0.75 mm or ≤ 0.90 mm or
MIC ratio > 0.40 and ≤ 0.80 MIC ratio > 0.45 and ≤ 0.80
Propane Group D MESG value > 0.75 mm or Group IIA MESG value > 0.90 mm or
MIC ratio > 0.80 MIC ratio > 0.80
Note: MESG values or MIC ratio criteria for group classification purposes were added to NFPA 497 (1997) and also incorporated into the
1999 edition of the NEC for consistency. Refer to C.6.1 for further explanation of MESG values and MIC ratios.
Table 9. Group Classifications of Dust Atmospheres per NEC Article 500

Dust Atmosphere Group
Atmospheres containing combustible metal dusts, including aluminum, magnesium, and their Group E
commercial alloys, or other combustible dusts whose particle size, abrasiveness, and conductivity
present similar hazards in the use of electrical equipment.
Atmospheres containing combustible carbonaceous dusts, including carbon black, charcoal, coal, or Group F
dusts that have been sensitized by other materials so that they present an explosion hazard.
Atmospheres containing combustible dusts not included in Group E or F, including flour, grain, wood, Group G
plastic, and chemicals.
Note: Where Group E dusts may be present in hazardous quantities, there are Division 1 locations only (i.e., no Division 2 locations). This
is because the release of conductive dust also can cause a simultaneous failure of the electrical equipment.

C.4 NEMA Classifications for Enclosures for Electrical Equipment

The following enclosure type numbers are assigned by NEMA (National Electrical Manufacturers Association)
to identify enclosures for some hazardous location electrical equipment.
Type 7. Enclosures constructed for indoor use in hazardous locations classified as Class I, Division I,
Groups A, B, C or D, as defined in the NEC.
Type 8. Enclosures constructed for either indoor or outdoor use in hazardous locations classified as Class
I, Division I, Groups A, B, C or D, as defined in the NEC.
Type 9. Enclosures constructed for indoor use in hazardous locations classified as Class II, Division I,
Groups E, F or G, as defined in the NEC.
Type 10. Enclosures constructed to meet the requirements of the Mine Safety and Health Administration,
30 CFR, Part 18.
These designations alone are not sufficient to determine suitability for use in a specific hazardous location.
These designations are historical terms approaching obsolescence and are not referenced by the NEC when
specifying the requirements for equipment selection. FM Global Research recommends that all hazardous
location electrical equipment be Approved or listed and labeled as specified in Section C.5. This may include
these type designations, but they must be supplemented by all of the marking requirements of the NEC.
C.5 FM Approvals
Electrical equipment is Approved by FM Approvals for either Class I or Class II locations, or both, and for
one or more atmosphere groups (A, B, C, D or IIC, IIB, IIA) for Class I hazardous locations or (E, F, or G)
for Class II hazardous locations. Surface temperatures of Approved equipment do not exceed the ignition
temperature of the specific gas, vapor, or dust for which the equipment is Approved. Electrical equipment
is marked to show the class, division or zone, group as applicable, and operating temperature or temperature
range for which it is Approved. Electrical equipment also can be specifically Approved and marked for Division
1 and 2 or Zone 0, 1 and 2 applications or for Division 2 or Zone 2 only. Electrical equipment that has been
Approved for a Division 1 or Zone 0 and Zone 1 location may be permitted in a Division 2 or Zone 2 location
of the same class and group as applicable.
There are types of electrical equipment which the NEC allows to be used in Class I, or II, Division 1 or 2
classified locations that do not require any special protection mechanisms, special markings or specific
listings. This type of equipment is commonly referred to as ‘‘nonsparking’’. Tables 5 and 7 (Section 2.3.2)
indicate many of the specific equipment types that need not be Approved or listed to be acceptable. Some
examples of frequently used non-Approved equipment include:
1. Some attachment plugs and receptacles which are not completely explosionproof and yet have been tested
and designed to be safe for use in Class I, Division 1 locations.
2. Electrical lighting fixtures in Class I, Division 2 locations with the exception of portable lighting equipment.
(Note that it must still be ensured that surface temperatures will not exceed 80% of the autoignition
temperature of the gas or vapor involved.)
3. Open squirrel cage or totally enclosed motors, fan cooled or not, are acceptable in Class I, Division 2
locations provided that they do not produce ignition-capable sparks or arcs under normal equipment operating
conditions.
4. Dust-tight enclosures in Class II, Division 2 locations are permitted for fuses, switches, motor controllers,
circuit breakers, push buttons, solenoids, control transformers, relays and other small devices. (See
Section C.4 for an enumeration of enclosures considered to be dust tight.)
5. Totally enclosed, pipe-ventilated motors for Class II, Division 2 locations.
6. ‘‘Simple apparatus’’ which will neither generate nor store more than 1.2 volts, 0.1 amps, 25 milliwatts or
20 microjoules need not be approved (e.g., thermocouple, LED).
There are various kinds of general purpose equipment that can be used in hazardous locations. The above
is just a guide and not a complete listing. The many exceptions can be found in the NEC.

C.6 Theoretical Background Information
C.6.1 General
The required energy for ignition of any flammable gas or vapor mixture primarily depends on the flammable
material, its concentration in air, its temperature and pressure just prior to ignition, and the prevailing electric
circuit ignition characteristics. Each vapor air mixture has a minimum value of energy that is required for
ignition. The minimum amounts of energy required to ignite some common flammable gases (i.e., Minimum
Ignition Energy or MIE at their most easily ignitable concentration) are given in Table 10 below. Below this
minimum, ignition of the mixture does not occur.
Electric spark ignition energy may be expressed in joules or millijoules. In a capacitive circuit, the energy
of a spark may be expressed as W = 1⁄2 CV2. W is the energy available in joules, C is the effective capacitance
in farads, V is the capacitance voltage in volts. MIE values for specific gases or vapors are determined using
a capacitive spark discharge. In an inductive current, W = 1⁄2LI2. W is the energy available in joules, L is
the effective inductance in henrys and I is the inductive current in amperes. MIC (Minimum Igniting Current)
values are determined using an inductive spark discharge. The MIC ratio is the ratio of the MIC value for
the specific gas or vapor of concern compared to the MIC value for methane when evaluated in the same
test apparatus. MIC values for Groups A through D and corresponding Groups IIC, IIB and IIA are given in
Table 8. MIC values for many other flammable gases and vapors are also provided in NFPA 497.
Table 10. Ignition Characteristics of Selected Gases

Minimum Ignition Energy MESG
Flammable Gas (millijoules) (mm)
Acetylene 0.017 0.25
Hydrogen 0.019 0.28
Ethylene 0.07 0.65
Propane 0.25 0.97
Methane 0.28 1.12
Ammonia 680 3.17
The Maximum Experimental Safe Gap (MESG) assumes the basic principle that ignition of a flammable
atmosphere can be prevented by separating an unburned flammable atmosphere from an ignition source
by a slit, screen or gauze material with very small openings. In general, the more ignitable a gas, the smaller
the openings are required to prevent a flame (or explosion) from passing through. Using this principle,
electrical equipment such as motors with commutators and switches can be made non-incendive by enclosing
the equipment in such a way that openings for shaft and switch operating mechanisms are very small.
Flat joints having a very small gap between mating surfaces in comparison to their width, present a flame
path along which an explosive mixture could travel. A flammable mixture ignited inside the enclosure would
be prevented from propagating flame through the gap to the outside of the enclosure. The amount of heat
absorbed from the hot gases by the flame path is dependent on the length of the flame path and the tightness
of the joint. The MESG for Groups A through D and corresponding groups IIC, IIB and IIA are given in Table
8. Typical values of the MESG for a 25 mm wide flame path that will not propagate an explosion through
a flameproof joint also are given for some flammable gases in Table 10. MESG values for many other
flammable gases and vapors also are also in NFPA 497.
The minimum ignition energy of most flammable gases and vapors as shown in Table 10 and NFPA 497 is
typically less than 1 mJ. In comparison, the minimum ignition energy for combustible dusts is considerably
higher, as illustrated by the few representative values shown in Table 11. On the other hand, the autoignition
temperatures (AITs) of many typical hydrocarbon solvent vapors are in the 450-500°C (850-950°F) range,
whereas the AITs of some typical dusts are below 250°C (500°F). The AIT ignition hazard of dusts is further
increased by the accumulation of deposits on equipment, leading to the possibility of smoldering due to
thermal instability. For this reason, the surface temperature requirements of equipment suitable for Class II
locations are based not only on the dust cloud ignition temperature, but also the dust layer ignition
temperature. Layer or cloud ignition temperatures for many common dusts are given in NFPA 499.
The practical implication of the comparison between dust and gas ignition properties is that the risk of ignition
from hot surfaces is much greater for dusts, while the risk of ignition from sparks is much greater for gases

and vapors. These very different ignition properties result in different designs for Class I and Class II
equipment. Unless Approved or listed for both classes, equipment Approved or listed for one class should
be assumed to be inappropriate for the other class.
Table 11. Minimum Ignition Energy of Selected Dusts1

Minimum Ignition Energy
Combustible Dusts (millijoules)
Aluminum 15
Magnesium 40
Grain 240
Coffee 160
Coal 60
Sulfur 15
1
Because the minimum ignition energies for dusts are dependent on particle size and shape, the values in the table should be considered
as illustrative only. The values should not be assumed to be correct for all individual situations involving the same materials.
C.6.2 Intrinsically Safe Equipment

Intrinsically safe equipment must meet two special conditions:
a) The energy available must be incapable of igniting the specified fuel-air mixture under ‘‘normal’’
operating conditions. ‘‘Normal’’ conditions include operations at maximum line supply voltage and the
environmental conditions that fall within the ratings given for the apparatus.
b) The energy available also must be incapable of igniting the specified fuel-air mixture under ‘‘abnormal’’
operating conditions. ‘‘Abnormal’’ or fault conditions include operations with any combination of two
independent mechanical or electrical faults occurring at the same time. If a defect or breakdown leads
to defects or breakdowns in other components, the primary and subsequent failures are considered to be
a single fault.
Intrinsically safe equipment involves relatively low levels of energy and is therefore limited to low voltage,
low current signal circuits. Typical equipment includes circuits for signaling, telephones and monitoring
equipment in hazardous locations.
C.7 Requirements in Countries Outside of the United States

Area classification in most countries as previously noted in Section 2.2 is based on ‘‘zones’’ rather than
‘‘divisions’’ which is now also recognized by NEC Article 505 for Class I locations. Although somewhat similar
approaches in concept, one important exception is that NEC Article 505 and the corresponding IEC/
CENELEC standards subdivide what are considered Division 1 areas by NEC Article 500 into two distinct
zones: Zone 0 and Zone 1. Zone 0 is defined as an area where the combustible mixture is continuously
present, or present for long periods (e.g., inside of a flammable liquid storage tank). Zone 1 is defined as an
area where the combustible mixture is likely to occur in normal operation (e.g., next to a periodically opened
access opening in a flammable liquids mix tank).
There are various markings for hazardous location electrical equipment, depending on the country of
equipment manufacture and intended use. However, one commonality in a great many countries are the
markings Ex (IEC) and EEx (CENELEC) to indicate equipment suitable for hazardous locations. The United
States uses the marking AEx for electrical equipment meeting NEC Article 505 using American National
Standards (ANSI test standards).
Testing and certification of equipment in all countries of Western Europe are performed to CENELEC
standards. EC member countries issue Certificates of Conformity to these standards and accept products
and systems certified by other members. Other countries either work to their own standards based on IEC
standards (e.g., Australia, Brazil, Japan, Russia) or accept products and systems certified to European and/or
American standards. Table 3 references the applicable test standards for the respective electrical equipment
protection concept employed by FM Approvals and other test/certification organizations to satisfy the
governing jurisdiction.
The system of marking applied to electrical apparatus satisfying NEC Article 505 or the corresponding
IEC/CENELEC area classification standard includes the following:

1. The symbol AEx, Ex or EEx which indicates that the electrical equipment corresponds to the applicable
ANSI, IEC or CENELEC test standards as noted in Table 3.
2. The sign to identify the method of protection:
o — oil immersion
p — pressurized apparatus
q — powder filling
d — flameproof enclosure
e — increased safety
ia — intrinsic safety, category a
ib — intrinsic safety, category b
m — encapsulation
3. The symbol of the group of the electrical apparatus: I (IEC and CENELEC only) for electrical apparatus
for mines susceptible to firedamp (gas mixture primarily methane) and II, IIA, IIB or IIC for electrical apparatus
for locations with a potentially explosive atmosphere other than mines susceptible to firedamp. The chemical
formula or name of the gas will follow the symbol II when the electrical apparatus is certified for use in only
a particular gas.
4. For Group II electrical apparatus, the symbol indicating the temperature class (i.e., T codes given in
Table 4) or the maximum surface temperature in °C, or both. The temperature class will be given last in
parenthesis if the marking includes both. For Group II electrical apparatus where the maximum surface
temperature is greater than 450°C, only an inscription of the temperature will appear.
The order of the markings will correspond to the order in which they are given above. Some examples of
markings are as follows:
• electrical apparatus in flameproof enclosure for Group IIC:
AEx d IIC (NEC Article 505)
Ex d IIC (IEC)
EEx d IIC (CENELEC)
Note: See Code column in Table 3 for other examples of different methods of protection.
• electrical apparatus in flameproof enclosure for Groups IIC, temperature class T3:
AEx or Ex or EEx d IIC T3
• increased safety electrical apparatus and a pressurized enclosure for group II with a maximum surface
temperature of 125°C:
AEx or Ex or EEx ep II 125°C (T4) or
AEx or Ex or EEx ep II 125°C
• flameproof enclosure for ammonia:
AEx or Ex or EEx d II(NH3)
C.8 NFPA Standards

There are no conflicts between this data sheet and the NEC with one exception. FM Global Research defines
volatile flammable liquids (C.2.1) to include liquids having a closed cup flash point of 100°F (38°C) and above
if heated higher than their flash point, while the NEC includes only Class II combustible liquids heated above
their flash point. Some guidelines for the application of judgement when establishing area classification are
different in this data sheet as compared to NFPA 497 and 499. Overall, guidelines in this data sheet are
less broadly sweeping, so as not to underclassify certain types of areas and occupancies.
C.9 Portable Electronic Products

All electrical equipment, including portable, low-voltage, battery-operated devices such as pages and cellular
phones, are considered as potential ignition sources in Class I or II, Division 1 or Zone 0 or 1 hazardous
locations unless specifically tested and FM Approved or listed for such use.

Portable, low-voltage, battery-operated devices meeting the requirements of ISA (The Instrumentation,
Systems and Automation Society) recommended practice (RP) 12.12.03 - 2002, can be used in Class I or
II, Division 2 or Zone 2 hazardous locations where FM Approved or listed devices are not available.
APPENDIX D BIBLIOGRAPHY
1. Electrical Installations In Hazardous Locations, Peter J. Schram and Mark W. Early, National Fire
Protection Association, 1991.
2. Hazardous Locations — Guide for the Design, Construction and Installation of Electrical Equipment in
Explosive Atmospheres, John Bossart, Canadian Standards Association, 1994.
3. ELECTRICAL SAFETY a guide to the causes and prevention of electrical hazards, J. Maxwell Adams,
The Institution of Electrical Engineers, 1994.
4. NFPA 497 (1997), Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors
and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas, National Fire
Protection Association, Quincy, MA.
5. NFPA 499 (1997), Recommended Practice for the Classification of Combustible Dusts and of Hazardous
(Classified) Locations for Electrical Installations in Chemical Process Areas, National Fire Protection
Association, Quincy, MA.
6. NFPA 496 (1998), Purged and Pressurized Enclosures for Electrical Equipment, National Fire Protection
Association, Quincy, MA.
7. Various publications of IEC TC 31, Electrical Apparatus for Explosive Atmospheres, as listed in the current
IEC Yearbook.
APPENDIX E THE THREE-ZONE CLASSIFICATION SYSTEM AND THE NATIONAL ELECTRIC CODE
The following paper was presented at the American Institute of Chemical Engineers 34th Loss Prevention
Symposium, Atlanta, March 5–9, 2000. This paper provides a description of the ‘‘Zone’’ classification system,
compares the ‘‘Zone’’ system to the traditional ‘‘Division’’ system and provides some discussion on the
application of the ‘‘Zone’’ system.

To be published in Chemical Engineering Progress, December 2000. Copyright © 2000 American Institute
of Chemical Engineers. All rights reserved. Not to be uploaded to any other site without permission from the
AIChE.
The Three-Zone Classification System and the National Electric Code®
John A. LeBlanc, Standards Division and

William G. Lawrence, Approvals Division
Factory Mutual Research
1151 Boston Providence Turnpike
Norwood, MA 02062
Prepared for Presentation at
American Institute of Chemical Engineers

34th Loss Prevention Symposium
Atlanta, GA
March 5-9, 2000
Copyright Factory Mutual Research Corporation
Date: November 1999
AIChE shall not be responsible for statements or opinions contained in papers or printed in its
publications

The Three-Zone Classification System and the National Electric Code®

John A. LeBlanc, Standards Division and
William G. Lawrence, Approvals Division
Factory Mutual Research
1151 Boston Providence Turnpike
Norwood, MA 02062
ABSTRACT
The National Electric Code® (NEC®), ANSI/NFPA 70, published by the National Fire Protection Association
(NFPA) allows two distinct approaches to classifying and installing electrical equipment in hazardous
(classified) locations. The 1996 edition of the NEC® provided the initial framework for the development of
the product standards for a three-Zone classification system based on the International Electrotechnical
Commission (IEC) 60079 series of standards. US deviations were introduced to align those standards with
NEC® and US practice. The 1999 edition of the NEC® has further refined the new “Zone” system. Electrical
equipment listed in accordance with the new “Zone” system is now available in the US. An understanding of
the similarities and differences between “Division” equipment and “Zone” equipment is needed to effectively
use these classification systems to protect facilities against unwanted electrical ignition sources in hazardous
(classified) locations.
The traditional US approach utilizes the two-Division classification system for hazardous locations. This
system has been in use since 1947 and is generally well understood. The new “Zone” system has been used
in much of the world for many years but has only limited acceptance in the US. The lack of acceptance is
largely based on a lack of understanding and the requirements of the NEC®. The NEC® requires that
hazardous locations be classified under either the traditional “Division” system or the new “Zone” system.
Since many existing installations were based on the “Division” system, “Zone” designed equipment could
generally not be introduced in those locations. The NEC® does, however, permit the use of “Division” classified
equipment in similar “Zone” areas. Reclassifying an area using the “Zone” system increases the number
of available options since both “Zone” and “Division” classified equipment may be used.
This paper will provide a description of the “Zone” classification system, compare the new “Zone” system
to the traditional “Division” system and provide some discussion on the application of the “Zone” system.
INTRODUCTION
The National Electrical Code® (NEC®), ANSI/NFPA 70, published by the National Fire Protection Association
(NFPA) is a set of uniform electrical installation rules written in a form that can be adopted into law. The federal
Occupational Safety and Health Administration (OSHA), all fifty states, and many local jurisdictions have
adopted, at least in part, the NEC® for electrical installation requirements. In addition to its applicability to
ordinary locations (unclassified), the NEC® provides the framework for approval, by jurisdictions, of electrical
equipment installations in hazardous (classified) locations and serves as the basis for the product standards
used by Nationally Recognized Testing Laboratories (NRTLs) to list equipment for approval by jurisdictions.
The NEC® allows two distinct approaches to classifying and installing electrical equipment in hazardous
locations containing flammable gases, vapors, or liquids. The original approach utilized the two-Division
classification system for hazardous locations. That system has been in use for many years and is generally
well understood. The 1996 edition of the NEC® provided the framework for the introduction of a three-Zone
classification system based on the International Electrotechnical Commission (IEC) 60079 series of
standards. This classification system only applied to flammable gases, vapors, and liquids. US deviations
were introduced into the appropriate product standards to align these IEC standards with NEC® and US
practice. The 1999 edition of the NEC® further refined the new “Zone” system.
The “Zone” system has been used in much of the world for many years Electrical equipment listed in
accordance with the new “Zone” system is now available in the US but availability remains limited. The lack
of acceptance is based on a lack of understanding and the requirements of the NEC®. The NEC® requires
that hazardous areas must be classified under either the “Division” system or the new “Zone” system. Since
many existing installations were based on the “Division” system, “Zone” designed equipment could not be
introduced. The NEC® does, however, permit the use of “Division” equipment in similar “Zone” areas.
Reclassifying an area using the “Zone” system increases the number of available options since both “Zone”
and “Division” equipment may be used. An understanding of the similarities and differences between
“Division” equipment and “Zone” equipment is needed to effectively use these systems to protect facilities
against unwanted electrical ignition sources.
Copyright © 2000 American Institute of Chemical Engineers. All rights reserved. Not to be uploaded to any other site without permission
from the AIChE.
DIVISION SYSTEM OVERVIEW

Under the “Division” system, flammable and combustible materials are first classified into three Classes of
materials.
Class I hazardous materials include gases, vapors and liquids that can burn or explode. Class II materials
include combustible dust, such as flour, sugar, aluminum magnesium. Class III materials include ignitable
fibers or ”flyings”, such as cotton lint.
Each of these three classes is further subdivided into two “Divisions”, with Division 1 encompassing hazards
that are continuously, intermittently, or periodically present in the atmosphere. Division 2 includes hazards
that can exist only under ”abnormal” circumstances. In other words, under this scheme, an area classified as
Class 1, Division 1 would represent the most hazardous area within its class.
The last subdivision within the “Division” classification system is the Group. Seven Groups are used to
categorize materials by similar physical characteristics. Groups A, B, C and D apply to Class I areas only.
Group A includes only acetylene. Group B includes gases such as hydrogen. Group C contains gases or
vapors such as ethyl ether, diethyl ether, ethylene, and ethylene oxide. Group D contains gases or vapors such
as propane, methane, gasoline, acetone, ethyl alcohol, hexane, butane, and ammonia.
Groups E, F, and G are the last three Groups and apply only to Class II areas where combustible dusts may
be found. Group E includes metals dusts such as magnesium. Group F contains the carbonaceous dusts
such as coal and coke dust. Group G includes the agricultural dusts such as flour. There are no groups defined
for Class III locations.
INTRODUCTION OF THE “ZONE” SYSTEM TO THE NEC®
Since the introduction of the two-Division area classification system in the 1947 NEC®, areas containing
potentially flammable gas atmospheres have been classified and apparatus has been designed to be applied
in Class I, Division 1 or Class I, Division 2 locations. With the introduction of the three-Zone area classification
into the IEC in the late 1960’s, there were informal discussions in the US concerning the introduction of the
system into US codes. The first proposals were prepared for the 1971 NEC®, but were rejected at that time.
For the next 25 years “Zone” proposals in various forms continued to be considered. Finally in 1996 a new
Article 505 was adopted which provided only the barest framework for the introduction of the “Zone” area
classification system. The definitions were included, but details such as marking and references to the
apparatus standards were not.
The possible introduction of the “Zone” area classification system into the 1996 NEC® provided the impetus
for the development of the US apparatus standards for the “Zone” types of protection. In 1994, one of the
American National Standards Institute (ANSI) Standards Developing Organizations, ISA – The International
Society for Measurement and Control, began development of a series of US standards based on the IEC
60079 series of standards, but with US deviations introduced to align with the NEC® and US practices. The
types of electrical equipment protection schemes that were included in the US standards are the same as
those defined in IEC 60079-0 and also in the similar European standard EN 50 014. The development effort
was completed with the issue of a series of standards in 1998. A second ANSI Standards Developing
Organization began a parallel effort in late 1995. They issued their standard in 1996. This standard did not
include the IEC text; it only provided the US deviations. It also did not include many of the US deviations
considered necessary to align with NEC® and US practices. There is now an ANSI mandated effort underway
to harmonize those two standards development efforts. The resulting standards are expected to be very close
to the current ISA standards and will be jointly published by both organizations.
“ZONE” SYSTEM OVERVIEW
In the US, the “Zone” system only applies to Class I locations. There is no equivalent “Zone” system for Class
II or III locations. There are three “Zone” classifications, Zone 0, Zone 1 and Zone 2. As shown in Table 1,
the “Zone” and “Division” classification systems defined by the NEC® are closely related. The table also
includes the “Zone” system that is used internationally. As should be expected, the US and IEC “Zone”
systems are, on the surface, identical. However, keep in mind that the IEC “Zone” system was only used
as guide for developing what was adopted in the NEC®. Numerous differences do exist between the US and
IEC “Zone” systems and electrical equipment listed in one system cannot be used by the other system without
an additional listing.
from the AIChE.

Table 1. Comparison of “Division” and “Zone” Area Classification Systems

Flammable Material Flammable Material
Present Continuously Present Intermittently Flammable Material
or for Long Periods of During Normal Present Only During
Standards Organization Time Operations Abnormal Operations
IEC/CENELEC* Zone 0 Zone 1 Zone 2
NFPA NEC® Article 505 Zone 0 Zone 1 Zone 2
“Zone” System
NEC® Article 500 Division 1 Division 2
“Division” System
*CENELEC: European Committee for Electrotechnical Standardization
COMPARISON OF “ZONE” SYSTEM AND “DIVISION” SYSTEM

Under the “Zone” classification system, Zone 2 is an area in which an explosive gas-air mixture is not likely
to occur under normal conditions and, if it does occur, will exist only for a short time. Class I, Zone 2 is
essentially the equivalent of Class I, Division 2. Even though there are minor differences in the various
protection techniques, the two classifications are handled interchangeably by the NEC®. The same is not true
for Class I Division 1 locations and Class I Zone 1 locations.
Class I, Division 1 can be considered to be subdivided into Zone 0 and Zone 1. Zone 0 defines those locations
in which an explosive gas-air mixture is present continuously or for long periods during normal operation.
An example of Zone 0 is the vapor space of a closed, but atmospherically vented, process vessel or storage
tank containing flammable material. By isolating the worst explosion hazards within Zone 0 classifications,
designers are free to use less restrictive and less costly systems in the remainder of Division 1 areas defined
as Zone 1, while limiting the type of protection permitted to Intrinsic Safety only in the more hazardous Zone
0 areas.
The full definitions for each “Zone” in the “Zone” classification system are provided in Table 2. Since prior
to 1996, all existing facilities in the US were classified using the “Division” classification system, the table also
provides a comparison of the two “Divisions” with the three “Zones”. Although the definitions provided in the
NEC® for the “Zone” system are more detailed, they do match up very well with the more generic “Division”
system definitions. The NEC® does however apply the two area classification systems differently. Some of the
key differences are listed below:
1. Classification of areas, selection of equipment and wiring methods, and installations using the “Zone”
classification system are required to be under the supervision of a qualified ‘Registered Professional
Engineer’ (PE). This is not the case for areas classified under the “Division” classification system or any
other electrical installation covered by the NEC®.
2. With few exceptions, the two area classification systems cannot be intermixed. A Class I, Zone 2 location
is permitted to abut, but not overlap, a Class I, Division 2 location. A Class I, Zone 0 or Zone 1 location
is not permitted to abut a Class I, Division 1 or Division 2 location.
3. Any location that is currently classified using the “Division” system can be reclassified as a Class I, Zone
0, Zone 1, or Zone 2 location provided all the space that is classified, because of a single flammable
gas or vapor source, is reclassified under the requirements of NEC® Article 505. Because of the potential
cost of reclassification, the introduction of the “Zone” classification system remains limited to new
installations and major revisions.
from the AIChE.

Table 2. NEC® Definitions of “Zone” and “Division” Classified Areas

Corresponding
Division Zone Definition/Examples of Use Area
1 0 Definition:
1) Areas in which ignitable concentrations of flammable gases of vapors are
present continuously; or
2) Areas in which ignitable concentrations of flammable gases or vapors are
present for long periods of time.
Examples:
1) Inside vented tanks or vessels that contain volatile flammable liquids;
2) Inside inadequately vented spraying or coating enclosures, where volatile
flammable solvents are used;
3) Between the inner and outer roof sections of a floating roof tank containing
volatile flammable liquids;
4) Inside open vessels, tanks and pits containing volatile flammable liquids;
5) Interior of an exhaust duct that is used to vent ignitable concentration of gases
or vapors;
6) Inside inadequately ventilated enclosures that contain normally venting
instruments utilizing or analyzing flammable fluids and venting to the inside of
the enclosure
1 Definition:
1) Areas in which ignitable concentrations of flammable gases of vapors are likely
to exist under normal operating conditions; or
2) Areas in which ignitable concentrations of flammable gases or vapors may exist
frequently because of repair of maintenance operations or because of leakage;
or
3) Areas in which equipment is operated or processes are carried on, of such a
nature that equipment breakdown or faulty operations could result in the release
of ignitable concentrations of flammable gases or vapors and also cause
simultaneous failure of electrical equipment in a mode to cause the electrical
equipment to become a source of ignition; or
4) Areas that are adjacent to a Zone 0 location from which ignitable concentration
of gases or vapors could be communicated, unless communication is prevented
by adequate positive pressure ventilation from a source of clean air and effective
safeguards against ventilation failure are provided. (applies to Zone 1)
Examples:
1) Locations where volatile flammable liquid or liquefied flammable gases are
transferred from one container to another;
2) In the vicinity of spraying and painting operation where flammable solvents are
used;
3) Adequately ventilated drying rooms or compartments for evaporation of
flammable solvents;
4) Adequately ventilated gas generator rooms;
5) Inadequately ventilated pump rooms for flammable gas or volatile flammable
liquids
2 2 Definition:
1) Areas in which ignitable concentrations of flammable gases or vapors are not
likely to occur in normal operation and if the do occur will exist only for a short
period; or
2) Areas in which volatile flammable liquids, flammable gases, or flammable vapors
are handled, processed, or used, but in which the liquids, gases, or vapors
normally are confined within closed containers or closed systems from which
they can escape, only as a result of accidental rupture or breakdown of the
container or system, or as a result of the abnormal operation of the equipment
with which the liquids or gases are handled, processed, or used; or
3) Areas in which ignitable concentrations of flammable gases or vapors normally
are prevented by positive mechanical ventilation, but which may become
hazardous as a result of failure or abnormal operation of the ventilation
equipment; or
4) Areas adjacent to Zone 1/Division 1 locations, from which ignitable concentration
of flammable gases or vapors could be communicated, unless such
communication is prevented by adequate positive-pressure ventilation form a
source of clean air, and effective safeguards against ventilation failure are
provided.

from the AIChE.

Protection Techniques
The specific rules for applying the “Division” and “Zone” classification systems must be clearly understood.
The differences in application are driven by the differences in protection techniques used on the electrical
equipment. Table 3 provides a listing of the allowed protection techniques for both systems. They each have
their own methodology for accomplishing the general equipment protection principle. In many cases, the
methodologies differ significantly and cannot be directly compared.
Intrinsic Safety.
Electrical equipment that is built using intrinsic safety is designed to be unable to ignite a flammable
atmosphere, even under specific fault conditions. This is accomplished by limiting the amount of electrical
energy used by or delivered to the device. Only equipment that uses the intrinsic safety protection scheme
is permitted in Zone 0 areas. However, caution must be used since there are two levels of intrinsic safety
that can be used. Electrical equipment that is specifically intended and tested for Zone 0 areas is identified
by using the letter “a” in the type of protection code for intrinsic safety (i.e., “ia”). Electrical equipment that
is specifically intended and tested for Zone 1 areas is identified by using the letter “b” in the type of protection
code for intrinsic safety (i.e., “ib”).
Flameproof.
“Flameproof” is a protection technique in the “Zone” system that is similar to “Explosionproof” under the
“Division” system. Equipment that is designed to be flameproof will resist an internal deflagration of a
flammable atmosphere without causing the ignition of an external flammable atmosphere. The ability to
contain an explosion and prevent ignition of a surrounding flammable atmosphere depends on the ability to
extinguish or cool an escaping flame front before it exits the equipment. Flame extinction is accomplished
by cooling the burning gases. The equipment designs to accomplish this cooling of the flame are tied to
specific flammable gases, vapors or liquids. As discussed in the next section of this paper, flammable vapors,
gases, and liquids are subdivided into Groups. “Zone” listed equipment is always marked with the acceptable
Group.
Increased Safety.
The increased safety protection technique was developed in Germany. It focuses on eliminating the potential
sources of ignition such as sparking, arcing or hot surfaces. The increased safety protection approach is
not directly comparable to any of the “Division” system protection schemes. Increased safety employs
increased creepage and clearance for electrical insulation, generously dimensioned contact surfaces, and
highly reliable connections to greatly reduce the likelihood of an ignition capable spark occurring. All increased
safety connections must be protected by an enclosure to reduce the possibility of contamination of the
electrical insulation that could result in a failure of the insulation. The enclosure must have a minimum degree
of protection of IP54 per IEC 60529 which provides a dust tight and water tight enclosure. This protection
is most commonly employed for connection terminals but also has applications in motor windings.
A Benefit of “Zone” Listed Equipment.
The combination of Zone 1 protection techniques allows the construction of small, light-weight, electrical
devices that can be readily combined into control panels without the need for the entire panel to be flameproof.
This allows the use of the best engineering approach to protect against any potential ignition source.
An example of how this approach can benefit an end user follows:
A Class I Division 1 fluorescent light fixture designed to be explosionproof has all of the electrical components
enclosed in an explosionproof case. A Class 1 Zone 1, fluorescent light fixture has each of its electrical
components individually protected using one of the “Zone” types of protection. The ballast is housed in its
own flameproof case with its wire terminals increased safety. The isolation switch is also flameproof with its
wire terminals increased safety. The bi-pin fluorescent lamps are connected using special sockets that meet
the requirements for increased safety. All of the fixture components are housed in a lightweight shatterproof
plastic case that provides degree of protection IP54 to reduce the likelihood of contamination of the electrical
insulation. This example demonstrates the significant reduction in the size and cost of electrical equipment
possible for Zone 1 locations in contrast to that required for Division 1 locations.
from the AIChE.

Table 3. Electrical Protection Techniques for the “Division” and “Zone” Systems
Permitted Zone/
Protection Technique Designation Division Standard Protection Principle
General Requirements AEx Zone 0, 1, & 2 ANSI/ISA S12.0.01
Division 1, 2 FM 3600
Explosion Proof (XP) Division 1, 2 FM 3615 Contain the
Flameproof d Zone 1, 2 ANSI/ISA S12.22.01 explosion and
Powder Filling q Zone 1, 2 ANSI/ISA S12.26.01 quench the flame
Increased Safety e Zone 1, 2 ANSI/ISA S12.16.01 No arcs, sparks, or
Non-sparking Equipment nA Zone 2 ISA S12.12.01 hot surfaces
Sparking Equipment nC Zone 2 ISA S12.12.01
w/protected contacts
Non-Incendive (NI) Division 2 FM 3611
Intrinsic Safety ia Zone 0, 1, 2 ISA S12.2.01 Limit energy of
Intrinsic Safety ib Zone 1, 2 ISA S12.2.01 sparks and surface
Intrinsically Safe Associated [ia] Non-Hazardous ISA S12.2.01 temperature
Apparatus
Intrinsically Safe Associated [ib] Non-Hazardous ISA S12.2.01
Apparatus
Intrinsic Safety (IS) Division 1, 2 FM 3610
(based on ISA
S12.2.01)
Restricted Breathing nR Zone 2 ISA S12.12.01 Keep flammable
Enclosure gas or vapor out.
Purged or Pressurized p Zone 1, 2 ANSI/NFPA 496
Type X, Y, Z Division 1, 2
Oil Immersion o Zone 1 ANSI/ISA S12.25.01
Encapsulation m Zone 1 ANSI/ISA S12.23.01
Group
There are other similarities between the two classification systems. Both systems provide an additional rating
that subdivides flammable gases and vapors into several Groups. Table 4 lists the “Zone” and “Division”
system Groups. As shown in Table 4, the Groups are quite similar in how the various gases or vapors are
subdivided. The largest difference is how acetylene and hydrogen are handled. Under the “Division” system,
each gas has its own Group, acetylene is in Group A, and hydrogen is in Group B. In the IEC “Zone” system,
both gases are in the same Group, acetylene and hydrogen are in Group IIC. In addition to the grouping
difference, Group IIC does not allow the use of flanged joints in flameproof equipment where as Group B
explosion proof equipment allows the use of flanged joints. In order to resolve these differences and continue
to allow the use of flanged joints, Group IIB equipment is also tested with hydrogen. This permits its use
in Group IIB atmospheres and also in hydrogen atmospheres. This equipment is marked IIB+H2.
Table 4. Comparison of “Division” and “Zone” Apparatus Grouping

NEC® Article 505 NEC® Article 500
Typical Gas or Vapor “Zone” Groups* “Division” Groups
Acetylene Group IIC Group A
Hydrogen (Group IIB + H2)** Group B
Ethyl ether, diethyl ether, ethylene, Group IIB Group C
and ethylene oxide
Propane, methane, gasoline, acetone, Group IIA Group D
ethyl alcohol, hexane, butane, and
ammonia
* Group I applies to environments found in underground mines which are not covered by the NEC®
** It should be noted that IIB + H2 is not a ‘Group’. Since the US has traditionally separated Acetylene and Hydrogen into two different Groups,
Group A and Group B; the closest approximation in the “Zone” system is to mark apparatus that is suitable for Hydrogen application as
suitable for IIB + H2. This is a common marking for flameproof apparatus that employs flanged joints not permitted in Group IIC.
from the AIChE.

Temperature Class
The last electrical equipment rating is temperature class. A comparison of the “Zone” and “Division”
temperature classes is presented in Table 5. The only real difference between the temperature classes in
the two systems is that the “Division” system allows for additional subdivision of temperatures.
Table 5. Temperature Class

NEC® NEC®
Maximum Surface Temperature Article 500 Article 505
450oC (842oF) T1 T1
300oC (572oF) T2 T2
280oC (536oF) T2A
260oC (500oF) T2B
230oC (446oF) T2C
215oC (419oF) T2D
200oC (392oF) T3 T3
180oC (356oF) T3A
165oC (329oF) T3B
160oC (320oF) T3C
135oC (275oF) T4 T4
120oC (248oF) T4A
100oC (212oF) T5 T5
85oC (185oF) T6 T6
Equipment Use
The use of electrical equipment in a “Zone” classified location is more limited by the NEC® than the equipment
for application in a “Division” classified location. Under the traditional “Division” system, apparatus only has
to be approved. Under the “Zone” system, apparatus has to be listed although there are exceptions for Zone
2 to allow the apparatus to be approved instead of listed. The NEC® differences between approved and listed
are important to understand.
The NEC® defines Approved as follows:
Approved — Acceptable to the authority having jurisdiction.
The NEC® defines Listed as follows:
Listed — Equipment, materials, or services included in a list published by an organization that is acceptable
to the authority having jurisdiction and concerned with evaluation of products or services, that maintains
periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose
listing states that either the equipment, material, or services meets identified standards or has been tested
and found suitable for a specified purpose.
With few areas classified using the “Zone” system, the market for apparatus using the IEC-based types of
protection in “Zone” classified areas remains limited and apparatus manufacturers continue to focus on the
“Division” system types of protection. In reality, the NEC® rules should not be a major limitation for apparatus
manufacturers or users. The NEC® permits “Division” apparatus to be used in similar “Zone” areas (see Table
6). Intrinsically Safe apparatus listed for Division 1 is permitted in Zone 0 locations, apparatus approved for
Division 1 is permitted in Zone 1 locations, and apparatus approved for Division 2 is permitted in Zone 2
locations. The requirement here for listed Intrinsically Safe Apparatus is not a penalty as almost all Intrinsically
Safe apparatus is indeed listed.
from the AIChE.

Table 6. Acceptable Use of Hazardous Location Electrical Equipment

Classified Location Acceptable Listed Equipment Acceptable Approved Equipment
Zone 0 Zone 0, Division 1 (intrinsically safe) None
Zone 1 Zone 0, Zone 1 Division 1
Zone 2 Zone 0, Zone 1, Zone 2 Division 1, Division 2
Division 1 Division 1 (intrinsically safe) Division 1
Division 2 Zone 0, Zone 1, Zone 2 Division 1, Division 2
This allowance provides additional equipment options for users if they reclassify existing hazardous
(classified) locations using the “Zone” system. In addition to having additional equipment choices, electrical
equipment that was designed using the Increased Safety “e” and Powder Filling “q” protection techniques
can offer significant size, weight, and cost reductions. These newly available “Zone” protection techniques
cannot be used in “Division” classified locations.
Marking Hazardous Area Electrical Equipment
Because of the potential for confusion with the introduction of the alternate “Zone” area classification system,
some changes were made to the marking detailed in IEC 60079-0 for use in the NEC®. The driving force
is that under the traditional “Division” system, the apparatus marking advises the installer which areas the
equipment can be installed in. A typical “Division” system apparatus marking is provided in Figure 1. Under
the IEC-based “Zone” system, the apparatus marking advises the installer what the type of protection is,
but does not detail where it can be used. The marking requirements introduced in Article 505 of the NEC®
combine the two methods of marking. In addition to the IEC-based marking, which is modified with the addition
of an “A” prefix before the “Ex” marking, the permitted Class and Zone are also added. A typical NEC®-based
“Zone” apparatus marking is provided in Figure 2.
Since “Division” apparatus is permitted in areas classified using the “Zone” classification system, a
supplemental “Zone” marking was also allowed. The marking consisted of the Class, Zone, Group, and
temperature class (T-Code) corresponding to the Class, Division, Group, and temperature class (T-Code)
of the “Division” system. The difference is the absence of the AEx and type of protection marking.
Figure 1 Marking Explanation for Division Classified Equipment
from the AIChE.

Figure 2 Marking Explanation for Zone Classified Equipment
Wiring Methods
Although the IEC types of protection for electrical equipment have been introduced into the US, it is critical
to note that the wiring methods permitted for this equipment remains the traditional US wiring method of
conduit with some limited application of cable. Many of the deviations introduced into the apparatus standards
are directly related to the need to interconnect with these traditional US wiring methods.
For wiring in NEC®-based Zone 0 locations, any of the wiring methods permitted for ordinary locations may
be used. Typical wiring methods employed are various types of non-armored cable, not unlike those used
in Europe. The apparent lack of requirements for Zone 0 wiring is based on the fact that all Zone 0 equipment
is intrinsically safe (i.e., low energy).
Beginning with the 1996 NEC®, some limited cable wiring methods were introduced for Division 1/Zone 1
locations. Metal-clad cable, Type MC, and Instrument Tray Cable, Type ITC, are both armored cable designs
with limited flexibility. However, they represent the first US application of other than conduit in a Division 1/
Zone 1 fixed applications.
For wiring in Division 2/Zone 2 locations, there are again some types of non-armored cable used, but for
most applications, the traditional conduit system is the most common wiring method.
CONCLUSION
Using the “Zone” system to classify hazardous areas increases the choices of electrical equipment available
for use in hazardous (classified) locations since both “Zone” and “Division” listed equipment is acceptable.
The added choices will can also reduce the overall cost of electrical installations in hazardous (classified)
locations since the protection techniques allowed in the “Zone” system can permit smaller, lighter, and less
costly equipment designs. The only way to utilize the advantages of the “Zone” system is to reclassify existing
hazardous (classified) locations in accordance with Article 505 of the NEC®.
from the AIChE.

As more areas are classified using the “Zone” system and more electrical equipment is certified to meet
the US requirements for IEC-based “Zone” types of protection, US apparatus and installations will migrate
towards the IEC-based “Zone” system. As the users prepare by classifying new installations and reclassifying
existing installations to take advantage of the new “Zone” apparatus, the manufacturers are also preparing.
Most of the major US companies manufacturing or marketing hazardous area electrical apparatus have
1)international operations producing IEC-based “Zone” apparatus, 2) alliances with international companies
producing IEC-based “Zone” apparatus, or 3) have purchased international operations to provide a source
of IEC-based “Zone” electrical apparatus. Unfortunately, moving to the “Zone” classification system will not
provide compatibility of equipment from other countries also using the IEC-based “Zone” system. There are
still numerous differences between the US system and the IEC systems for equipment. Because of all the legal
ramifications involved in national certifications, equipment that is certified to meet the IEC-based requirements
of other countries will need to be re-certified to meet the US requirements.
ADDITIONAL READING
1. ANSI/NFPA 70, “National Electrical Code®,” National Fire Protection Association, 1999 Edition
2. Earley, M. W., Sheehan, J. V., Caloggero, J. M., “National Electric Code Handbook,” National Fire Protection
Association, 1999 Edition
3. NFPA 497, “Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors and
of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas,” National Fire
Protection Association, 1997 Edition.
4. API Recommended Practice 500 (RP500), “Recommended Practice for Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as Class I, Division 1 or Division 2,” American
Petroleum Institute, November 1997, Second Edition.
5. ANSI/API RP505, “Recommended Practice for Classification of Locations for Electrical Installations at
Petroleum Facilities Classified as Class I, Zone 0, Zone 1 or Zone 2,” American Petroleum Institute, 1998,
First Edition.
6. FM Global Property Loss Prevention Data Sheet 5-1, “Electrical Equipment in Hazardous (Classified)
Locations.”
7. “Approved Product News — In the Zone with FMRC,” Factory Mutual, 1998, Volume 14, Number 3.
http://www.fmglobal.com/pdfs/apn14_3.pdf
8. “Approved Product News – Interlaboratory Agreements – International Hazardous Location Standards,”
FM Global, 1999, Volume 15, Number 3. http://www.fmglobal.com/pdfs/apn15_3.pdf
from the AIChE.

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Property Loss Prevention Data Sheets 5-1

ELECTRICAL EQUIPMENT IN HAZARDOUS (CLASSIFIED) LOCATIONS

1.0 SCOPE ................................................................................................................................................... 3

APPENDIX D BIBLIOGRAPHY ................................................................................................................. 25

©2006 Factory Mutual Insurance Company. All rights reserved.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1.1 Referenced NFPA or International and National Standards

2.1.2 Exceptions to Application of Data Sheet 5-1

©2006 Factory Mutual Insurance Company. All rights reserved.

2.2.1 Classification of Hazardous Locations: Class I and Class II Hazardous Locations

2.2.1.1 Class I Hazardous Locations

©2006 Factory Mutual Insurance Company. All rights reserved.

©2006 Factory Mutual Insurance Company. All rights reserved.

2.2.1.2 Class II Hazardous Locations

Table 2. Classification Guidelines Based on Depth of Dust Accumulations

2.3 Equipment and Processes

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2.3.2 Specific Electrical Wiring and Equipment Requirements

2.3.2.1 Class I Hazardous Locations

©2006 Factory Mutual Insurance Company. All rights reserved.

Table 4. T Codes (Temperature Identification Numbers)

©2006 Factory Mutual Insurance Company. All rights reserved.

©2006 Factory Mutual Insurance Company. All rights reserved.

2.3.2.2 Class II Hazardous Locations

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Table 6. Surface Temperature Limits

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2.3.3.1 General Requirements for Pressurized Enclosures

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2.3.3.2 Specific Requirements for Pressurized Enclosures in Class I Locations

©2006 Factory Mutual Insurance Company. All rights reserved.

2.3.3.3 Specific Requirements for Pressurized Enclosures in Class II Locations

2.4 Operation and Maintenance

3.0 SUPPORT FOR RECOMMENDATIONS

4.2 NFPA Standards

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APPENDIX A GLOSSARY OF TERMS

APPENDIX B DOCUMENT REVISION HISTORY

APPENDIX C SUPPLEMENTARY INFORMATION

C.2 Explanatory Material

©2006 Factory Mutual Insurance Company. All rights reserved.

C.2.1 Class I Hazardous Locations

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C.2.2 Class II Hazardous Locations

C.2.3 Nonclassified Locations

©2006 Factory Mutual Insurance Company. All rights reserved.

C.2.4 Purged and Pressurized Enclosures as covered by NFPA 496

C.2.4.2 Purged and Pressurized Enclosures for Class I Locations

C.2.4.3 Purged and Pressurized Enclosures for Class II Locations

C.2.5 Intrinsically Safe Electrical Equipment

©2006 Factory Mutual Insurance Company. All rights reserved.

C.2.6 Non-Incendive Electrical Equipment

C.2.7 Explosionproof Equipment

C.2.8 Dust-ignitionproof Equipment

C.2.9 Other Protected Types of Electrical Equipment

©2006 Factory Mutual Insurance Company. All rights reserved.

C.3 Group Classification

Table 8. Group Classifications for Flammable Gas and Vapor Atmospheres

Table 9. Group Classifications of Dust Atmospheres per NEC Article 500