Thomas & Betts Kopex - Understanding Hazardous Areas & Specifying Flexible Conduit

Technical Guide
Understanding Hazardous Areas
& Specifying Flexible Conduit
10387 T&B KOPEX EX UHA CATALOGUE 2011.indd 310387 T&B KOPEX EX UHA CATALOGUE 2011.indd 3 19/08/2011 15:4119/08/2011 15:41

Welcome to
Thomas & Betts
At Kopex International we have been a manufacturer and
supplier of electrical conduit systems since 1947, and have
become a recognized authority in all aspects of conduit
system specification, design and manufacture.
As a world leader, Kopex offers an outstanding range of
metallic and non-metallic conduit fittings and accessories
for all applications including hazardous areas under its
KOPEX-EX range. Kopex-Ex offers global support with
distributors and stockists in all areas of the world. If you
are ordering products, looking for advice or making a
general enquiry, Kopex-Ex distributors are fully trained
in all aspects of the product range.
Our rigorous quality standards and a dedicated design and
development programme ensure that Kopex-Ex products
are not only of the highest specification and reliability,
but also meet many of the worldwide standards laid out
in this guide. Kopex-Ex is part of the global Thomas & Betts
corporationwhichexcelsindeliveringcriticalsystemprotection
across industrial and automotive applications, with leading
brands such as Adaptaflex and Harnessflex.
The company is certified ISO 9001 quality standard and
EN 14001 environmental standard, IECEx Operational
Document OD 005 and EN13980 Quality Systems for
Manufacturers.
Introduction
2

Thomas & Betts • tel +33 (0)1 64 40 27 26 • fax +33 (0)1 64 40 20 11 • sales@tnb.com • www.tnb.com/ex
Contents
33
Contents
Section 1 Introduction to Hazardous Areas 4 - 7
1.1 Explosive Atmospheres 4
1.2 Understanding Installations 5
1.3 Product Marking Guide 6 - 7
Section 2 Standards and what they mean 8 - 21
2.1 ATEX 8 - 13
2.2 Hazardous Areas Class and Division or
Class and Zone 14 - 20
2.3 IECEx 21
3.4 UL & CSA 21
3.5 GOST 21
Section 3 Equipment v Component 22 - 23
3.1 Kopex-Ex Classifications 22
3.2 UL/CSA Classifications 23
Section 4 Conduit v Cable 24 - 25
4.1 Choosing Cable 24
4.2 Choosing Conduit 25
Section 6 Applications of Products 26
Section 7 Product Features and Benefits 27
Section 9 Services We Offer 28 - 29

Section 1 - Introduction to Hazardous Areas
The information given in this catalogue is intended to give
an insight into the products offered by Kopex-Ex for use in
hazardous areas. We will outline the areas that are designated
as hazardous, explain the reasons for the designation
and the supporting legislation. Further to this we will
outline what products can be used, as well as pointing out
potential advantages in using our products over those of our
competitors.
Please note that we can only give general advice on the
requirements of our products and we presume that the
personnel working in these areas are fully qualified with the
necessary level of competency in the field. It should also be
highlighted that in normal circumstances, it is the Plant Owner
or Operator who is responsible for the safe operation of the
plant and that all products used meet the necessary codes
of practice.
Section 1
Introduction to Hazardous Areas
1.1 Explosive Atmospheres
The danger of explosion exists in all hazardous areas and it
is important to understand what constitutes an explosive
atmosphere. This occurs when gas, vapour, mist, dust or
flyings are mixed with air in such proportions that it has the
potential to catch fire or explode.
Three things need to be present for an explosion to occur:
1. Flammable gas, vapour, mist, dust or flyings with
2. Air in the correct ratio, ignited by an
3. Ignition source (i.e. electrical spark)
This is commonly known as the
“Ignition Triangle”.
Flammable Materials
The classification of flammable materials includes several key
characteristics including:
• Relative Density: This is the density of the gas, vapour or
dust relative to the density of air.
• Flash Point: This is the minimum temperature at which a
vapour, air mixture forms over the surface of the liquid, that
can be ignited by a seperate source.
• Flammable Limit: This is the upper and lower explosive
limits at which a substance will ignite (mixture percentage
of gas / dust to air), i.e. methane LEL 4.4%, UEL 17%.
Minimum Ignition Energy (MIE)
This is the lowest energy which is sufficient to effect ignition
of the most easily ignitable explosive atmosphere under
specified test conditions.
Sources of Ignition
There are many sources of ignition which can cause an
explosion these include:
• Sparks • Electrical arcs
• Heat from the sun • Static charge
• Open flames • Engine exhausts
• Chemical reaction
Fuels
IgnitionSources
Oxidizers
4

1.2 - Understanding Installations
In operation it is the responsibility of the operator to ensure
that the conditions to cause an explosion do not arise.
However, due to the fact that there is a risk of these events
occurring measures need to be taken in respect of electrical
and non-electrical products to prevent ignition.
So what does the operator need to think about when
providing a safe environment?
1. In the principle design of any plant all hazards and risks
should be reduced to a minimum.
2. When installing electrical plant equipment it should be
installed, where possible, in non hazardous areas. If this is
not an option, the least hazardous area possible should be
selected (See Zones for further details).
3. All electrical equipment and wiring connections need to be
designed, installed, operated and maintained so that they
do not become an ignition source.
There are three further requirements that electrical equipment
has to follow:
1. Construction and installation has to comply with the
regulations and requirements for use in a hazardous areas
(This may be country specific).
2. All electrical products have to be installed to the
manufacturers instructions, and follow any constraints/
limitations that any certification requires. (For example if
the product is certified as a component then the piece of
equipment that it is attached to may need to be tested and
certified with this component in-situ).
3. On completion of an installation, an inspection should be
carried out by a competent body.
Zones / Class
Hazardous Zones/Class are defined in order to assess their
risk, instigating the relevant measures to prevent ignition of
flammable gases and dusts. The classifications of zones
and divisions are laid down in the relevant standards. The
classification of zone or division can comprise the following:
1. Area classification drawings.
2. Information on ventilation/air conditioning that may effect
a hazardous area.
3. Details on the sources of release of gases and dusts.
4. Details of the flammable substances stored or being handled.
Understanding Installations
5

CMPL I M2/II 2GD Exde I Mb Exde IIC Gb Extb IIIC Db
CLI.Div1.ABCD .CLII.Div1.EFG.
Gases or vapours
Subdivision of gases and vapours
Typical
zones
Temporary behaviour of
flammable substances in
hazardous places
Flammable
substances
Methane
Dusts
Required marking for installation
equipment equipment
group protection level
IIA
IIB
IIC
is present continuously or zone 0 II Ga
for long periods or frequently
is likely to occur in normal zone 1 II Gb
operation occasionally
is not likely to occur in normal
opration but, if it does occur, will zone 2 II Gc
persist for a short period only
is present continuously or for zone 20 III Da
for long periods or frequently
is likely to occur in normal zone 21 III Db
operation occasionally
it is not likely to occur in normal
operation but, if it does occur, zone 22 III Dc
will persist for a short period only
- mines I Ma
- mines I Mb
Dusts
Gases
Vapours
Apparatus may
be used in group
Dust
IIIA Combustible Flyings
IIIB Non-Conductive Dust
IIIC Conductive Dust
ammonia ethyl alcohol galsoline acetaldehyde
methane cyclohexane n-hexane
ethane n-butane
propane
town gas, ethylene ethylene ethyl-ether
acrylnitril ethylene glycol
oxide
sulphide ofethinehydrogen
carbon(acetylene)
(Product stamp detail)
(Class & Divisions)
Classification of hazardous areas European/IEC or NEC classifications
Classification of equipment
for use in potentially explosive atmospheres
CLI (Class I), Div1
Where ignitable concentrations of flammable gases, vapors or liquids
are present within the atmosphere under normal operation conditions.
CLI (Class I), Div2
Where ignitable concentrations of flammable gases, vapors or liquids are
present within the atmosphere under abnormal operation conditions.
Class I Areas
Group A: Acetylene / Group B: Hydrogen /
Group C: Propane & Ethylene / Group D: Benzene, Butane & Propane.
CLII (Class II), Div1
Where ignitable concentrations of combustible dusts are present within
the atmosphere under normal operation conditions.
CLII (Class II), Div2
Where ignitable concentrations of combustible dusts are present
within the atmosphere under abnormal operation conditions.
Class II Areas
Group E: Metal Dust / Group F: Carbon & Charcoal / Group G: Flour,
Starch, Wood & Plastic.
1.3 - Product Marking Guide
6

Liquid Tight Hazardous Areas Gland
IECEx SIRA09.0103 X
All applications
Control stations, motors, fuses,
switchgear, power electronics
Installation materials, motors, luminaries
Measurement and control, automation
technology, sensors, actuators
Switch- and control cupboards,
analyse-apparatus, computers
Coils of motors or relays, solenoid valves
Transformers, relays, control stations,
magnetic contactors
Capacitors, transformers
Product use depending on
temperature class (T1 - T6).
See at the top - only for zone 2
Temperature Class (T) / Ignition Temperature
Restriction
for using apparatus
Requirements Marking
Equipment without
Equipment with
-
restriction
special condition X
may be noted
Ex component,
which is not
intended to be
used alone
and requires
additional
certification before
U
being used in
hazardous area
-
Exd
Exe
Exi
Exp
Exm
Exo
450º
Exq
Exn
60079-0
60079-1
60079-7
60079-11
60079-2
60079-18
60079-6
60079-5
60079-15
General requirements
Flameproof enclosure
Increased safety
Intrinsic safety
Pressurisation
Encapsulation
Oil immersion
Powder filling
‘Non sparking’
For use in zone 0, 1, 2 / for use in zone 1, 2 Ext 60079-31Dust atmospheres
IIA T1 Acetone 735º
IIA T1 Ammonia 630º
IIB T1 Carbon Monoxide 605º
IIA T1 Bensene 560º
IIC T1 Hydrogen 560º
IIA T1 Methane 537º
IIA T1 Toluene 535º
IIA T1 Styrene 490º
IIA T1 Propane 470º
IIA T1 1-Butene 455º
IIB T1 Butadiene 430º
IIB T2 Ethylene 425º
IIA T2 Butane 372º
IIA T2 Ethanol 363º
IIA T2 Butylalcohol 359º
IIB T2 Dimetylether 350º
IIC T2 Acetylene 305º
IIA T3 Nafta 290º
IIA T3 Hydrogen Sulphide 270º
IIA T3 Cyclohexane 259º
IIA T3 Hexane 233º
IIA T3 Heptane 215º
IIA T3 Kerosene 210º
IIA T3 Dekane 201º
IIB T4 Diethyl Ether 160º
IIC T6 Carbon Disulphide 95º
Application Marking EN/IEC standardType of protection
Protection technique
(Certification Number)
300º
200º
135º
100º
85º
T1 > 450º
T2 > 300º
T3 > 200º
T4 > 135º
T5 > 100º
T6 > 85º
600º
750º
New Marking - EPL’s
(Explosion Protection Levels)
The introduction of the EPL’s and changes in the
EN 60079 series standard has introduced new
marking requirements.
7

Section 2 - Standards and what they mean
In this Section we will outline the different Standards used
throughout the world and what it means for products
specified for use in Hazardous Areas. Below is a map of the
world which illustrates the Standards that are generally used in
these regions.
Section 2.1 - The ATEX Europe Directives 94/9/EC
ATEX requires employers to eliminate or control risks from
dangerous substances and to classify areas where explosive
atmospheres may occur into zones, as laid down in regulations.
ATEX Directives are designed to protect employees, the public
and the environment from accidents owing to explosive
atmospheres and since July 1st 2006 all existing sites, as well as
new sites, must be fully ATEX compliant.
Directive ATEX100a applies to equipment suppliers and
manufacturers and ATEX137 applies to end users. These
directives compliment each other, but have different purposes.
ATEX100A covers both electrical and non-electrical products
intended for use in hazardous areas, including mechanical
equipment. The Directive came into existence in 2003 and
products sold within the European Union designed for use in
hazardous areas must have ATEX certification and bear the
Section 2
Standards and what they mean
ATEX marking on the product or on a certificate plate. The
obligation is placed upon the manufacturer or supplier of the
product and the intention is to facilitate free movement of
goods within the EU.
Declaration of Conformance
This has to be issued by the supplier for every order which
is to be installed in a hazardous area. This document has to
show that the equipment supplied complies with the latest
harmonized standard.
UL CSA
Product Approvals
IECEx GOST INMETROATEX
8

FOR DUST
ZONE 20
Permanent / Frequent
Area in which an explosive
atmosphere in the form of a cloud of
combustible dust in air is present continuously,
or for long periods, or frequently.
SAFETY ZONE
No Explosion Risk
ZONE 21
Occasional
atmosphere, in the form of a cloud
of combustible dust in air is likely to occur,
occasionally, in normal operation,
ocassionally.
ZONE 22
DustIrregular/ShortDuration
atmosphere, in the form of a cloud of
combustible dust in air is not likely to occur
in normal operation but, if it does occur,
will persist for a short period only.
Zone Deﬁnitions
Dust (as per ATEX 60079-10)
Zones for Dust
9

FOR GASES & VAPOURS
ZONE 0
Permanent / Frequent
Place in which an explosive
atmosphere consisting of a mixture with air
of flammable substances in the form of gas,
vapour or mist is present continuously or for
long periods, or frequently.
ZONE 1
Ocassional
Site where an atmosphere
consisting of a mixture of air and
inflammable substances in the form of gas,
vapour or mist is likely to arise occasionally
during normal operation.
Zones for Gases & Vapours
Zone Deﬁnitions
Gases & Vapours (as per ATEX 60079-10)
10

SAFETY ZONE
Low Explosion Risk
ZONE 2
Gas Irregular / Short Duration
Place in which an explosive
atmosphere consisting of a mixture with air
of flammable substances in the form of gas,
vapour or mist is not likely to occur in
normal operation but, if it does occur, will
persist for a short period only.
11

Forms of Protection
Safety can be adhered to using two methods: either locating
the equipment in a safe area outside the hazardous area, or by
having the equipment designed, installed and maintained to
the standards for that area. There are a number of standards
that equipment can be designed to meet. To understand this
we need to explain the different forms of protection.
Exd (Flameproof Enclosure Type d)
Enclosures which contain electrical products which may
arc or spark in an atmosphere that may be explosive. The
construction of which needs to be designed, so preventing
transmission of an explosion to the explosive gas
atmosphere surrounding the enclosure. This equipment must
be inspected to ensure that the integrity of the product is
maintained as per manufacturers instructions.
Exe (Increased Safety Enclosures Type e)
This relates to enclosures which may have mixtures of
explosive dusts and gases within them but are not designed
to withstand an internal explosion. Instead, the likelihood of
explosion is reduced by the following conditions:
• Components ﬁtted within the enclosure shall not produce
a spark/arc in normal operation which is of a high enough
energy to ignite an explosive atmosphere.
• Electrical equipment should maintain a high level of
reliability within the enclosure.
• Electrical enclosures need to meet a minimum level of
ingress protection IP54.
• Electrical enclosures should have a high impact resistance.
Exde
A combination of Exd and Exe type enclosures.
Exi
This applies to intrinsically safe equipment. These are products
that incorporate circuits which due to low energy potential
are not capable of igniting an explosive atmosphere.
This section is split down into Ex ia for equipment in Zone
0/20, Ex ib for Zone 1/21 and Ex ic for Zone 2/22.
Forms of Protection
Atex Kopex-Ex Products
Range Name ATEX Number Standard
Nylon conduit systems BASEEFA08 ATEX0003X EN60079-0:2006
Anti-static EN60079-7:2007
EN61241-0:2006
EN61241-1:2004
Flameproof BASEEFA06 ATEX0256X EN60079-0:2004
Conduit glands EN60079-1:2003
Group II EN60079-7:2001
EN61241-0:2004
EN61241-1:2004
Group I glands SIRA09A ATEX1231X EN60079-0:2009
G1, E, U EN60079-1:2007
EN60079-7:2007
EN60079-31:2008
Thread convertors BASEEFA07 ATEX0247X EN60079-0:2006
Reducers EN60079-1:2004
Enlargers EN60079-7:2003
+ Amendments
EN61241-0:2004
EN61241-1:2004
Standard BASEEFA08 ATEX6324 EN60079-0:2004
stopping plugs EN60079-1:2007
Tamperproof BASEEFA08 ATEX6324 EN60079-0:2004
Hex head BASEEFA08 ATEX0325X EN60079-0:2006
EN61241-0:2004
EN61241-1:2004
Dome head BASEEFA08 ATEX0325X EN60079-0:2006
EN61241-0:2004
EN61241-1:2004
Nylon cable glands SIRA00 ATEX1072X
Nylon stopping plugs SIRA00 ATEX1074X EN50014:1997
EN50018:2000
EN50019:2000
EN50281-1-1:1998
12

Kopex-Ex Products to Zones Comparisons Chart
Zones Products
Zone 0 No products Certified
Zone 20
Zone 1 Nylon conduit systems Liquid tight conduit systems Thread convertors
Zone 2 Standard stopping plugs Tamperproof stopping plugs Hex head stopping plugs
Zone 21 Dome head stopping plugs Nylon glands Nylon stopping plugs
Zone 22
Kopex-Ex Protection Table
Zones Products
Exe (Increased Safety) Designed to Prevent Ignition Nylon conduit systems
Liquid tight conduit glands
Thread convertors
Hex head stopping plugs
Dome head stopping plugs
Nylon glands
Nylon stopping plugs
Exd (Flameproof Enclosure) Designed to Prevent Transmission Liquid tight conduit glands
Conduit gland
Thread convertors
Standard stopping plugs
Tamperproof stopping plugs
Ext (Dust Environment) Nylon conduit systems
Conduit glands
Thread convertors
Standard stopping plugs
Tamperproof stopping plugs
13

Section 2.2 - Hazardous Areas Class and Division
or Class and Zone
Class I Div 1
Location:
1. In which ignitable concentrations of flammable gases or
vapours can exist under normal operating conditions.
2. In which ignitable concentrations of such gases or vapours
may exist frequently because of repair or maintenance
operations or because of leakage.
3. In which breakdown or faulty operation of equipment or
processes might release ignitable concentration of
flammable gases or vapour and might also cause
simultaneous failure of electrical equipment in such a way
as to directly course the electrical equipment to become
a source of ignition.
Class I Div 2
Location:
1. In which volatile flammable liquids or flammable gases are
handled, processed, or used, but in which the liquids,
vapours or gases will normally be confined within closed
containers or closed systems from which they can escape
only in case or accidental rupture or breakdown of such
containers or systems or in case of abnormal operation
of equipment.
2. In which ignitable concentrations of gases or vapours are
normally prevented by positive mechanical ventilation and
which might become hazardous through failure or
abnormal operation of the ventilation equipment.
3. That is adjacent to a Call I Div 1 location, and to which
ignitable concentrations of gases or vapours 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.
Hazardous Areas
Class and Division or Class and Zone
Class II
Locations are those that are hazardous because of the
presence of combustible dust.
Class II Div 1
Location:
1. In which combustible dust is in the air under normal
operating conditions in quantities sufficient to produce
explosive or ignitable mixtures.
2. Where mechanical failure or abnormal operation of machinery
or equipment might cause such explosive or ignitable mixtures
to be produced, and might also provide a source of ignition
though simultaneous failure or electric equipment, through
operation of protection devices, for from other causes.
3. In which Group E combustible dusts (metal dusts such as
aluminium, magnesium and their alloys) may be present in
quantities sufficient to be hazardous.
Class II Div 2
Location:
1. In which combustible dust due to abnormal operations
may be present in the air in quantities sufficient to produce
explosive or ignitable mixtures.
2. Where combustible dust accumulations are present but are
normally insufficient to interfere with the normal operation
of electrical equipment or other apparatus, but could as a
result of infrequent malfunctioning of handling or
processing equipment become suspended in the air.
3. In which combustible dust accumulations on, in, or in the
vicinity of the electrical equipment could be sufficient to
interfere with the safe dissipation of heat from electrical
equipment, or could be ignitable by abnormal operation or
failure of electrical equipment.
Class III
Locations are those that are hazardous because of the
presence of easily ignitable fibres or flyings, but in which such
fibres or flyings are not likely to be in suspension in the air in
quantities sufficient to produce ignitable mixtures.14

Class III Div 1
Location in which easily ignitable fibres or materials producing
combustible flyings are handled, manufactured or used.
Includes rayon, cotton, jute, hemp, cocoa fibre and similar
materials.
Class III Div 2
Is a location in which easily ignitable fibres are stored or
handled other than in the process of manufacture.
Class I Group Classifications
Group A - Acetylene
Copper(I) acetylide, or cuprous acetylide, is an inorganic
chemical compound with the formula Cu2C2. It is a heat
and shock sensitive high explosive, more sensitive than silver
acetylide. Copper acetylide can be prepared by passing
acetylene gas through copper(I) chloride solution in presence
of ammonia: C2H2 + 2CuCl → Cu2C2 + 2HCl
Copper acetylide can form inside pipes made of copper or an
alloy with high copper content, which may result in violent
explosion. This was found to be the cause of explosions in
acetylene plants, and led to abandonment of copper as a
construction material in such plants. Copper catalysts used in
petrochemistry can also possess a degree of risk under
certain conditions.
Group B
Flammable gas, flammable liquid produced vapour or
combustible liquid produced vapour mixed with air that may
burn or explode, having either a max experimental safe gap
(MSEG) value less than or equal to 0.45mm or min igniting
current ratio (MIC ratio) less than or equal to 0.40.
Group C
(MSEG) value greater than 0.45mm and less than or equal to
0.75mm, or min igniting current ratio (MIC ratio) greater than
0.40 and less than or equal to 0.80.
Group D
(MSEG) value greater than 0.75mm, or min igniting current
ratio (MIC ratio) greater than 0.80.
Group Classifications
15

Class II Group Classifications
Group E
Atmospheres containing combustible metal dusts, including
aluminium, magnesium, and their commercial alloys, or other
combustible dusts whose particle size, abrasiveness, and
conductivity present similar hazards in the use of electrical
equipment.
Group F
Atmospheres containing combustible carbon aceous dusts
that have more than 8 percent total entrapped volatiles or that
have been sensitized by other materials so that they present
an explosion hazard. Coal, carbon black. Charcoal and coke
dusts are examples of carbonaceous dusts.
Group G
Atmospheres containing combustible dusts not included
in Group E or F, including flour, grain, wood, plastic and
chemicals.
Group Classifications
Protection Techniques
Explosionproof Apparatus - Class I Div 1 or Div 2
Apparatus enclosed in a case that is capable of withstanding
an explosion of a specified gas or vapour that may occur
within it and of preventing the ignition of a specified gasor
vapour surrounding the enclosure by sparks, flashes or
explosion of the gas or vapour within, and that operates at
such an external temperature that a surrounding flammable
atmosphere will not be ignited thereby.
Dust Ignition Proof - Class II Div 1 or Div 2
Equipment enclosed in a manner that excludes dusts and
does not permit arcs, sparks, or heat otherwise generated or
liberated inside of the enclosure to cause ignition of
exterior accumulations or atmospheric suspensions of a
specified dust on or in the vicinity of the enclosure.
Dust Tight - Class II Div 2 or Class III Div 1 or Div 2
Enclosures constructed so that dust will not enter under
specified test conditions.
16

Class I Zone 0, Zone 1 and Zone 2 Locations
Class I Zone 0
Location in which ignitable concentrations of flammable gases
or vapours are present continuously or for long periods of
time, i.e. Locations inside vented tanks or vessels.
Class I Zone 1
Location in which ignitable concentrations of flammable
gases or vapours are likely to exist under normal operating
condition.
Location in which ignitable concentrations of flammable gases
or vapours are likely to exist frequently because of repair or
maintenance operations or because of leakage.
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 vapours and also cause simultaneous
failure of electrical equipment in a mode to cause the electrical
equipment to become a source of ignition.
That is adjacent to a to a Class I Zone 0 location from which
ignitable concentrations of vapours 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.
Class I Zone 2
In which ignitable concentrations of flammable gases or
vapours are not likely to occur in normal operation and if they
do occur will only for a short period of time.
In which volatile flammable liquids, flammable gases, or
flammable vapours are handled, processed, or used but in
which the liquids, gases, or vapours normally are confined
within closed containers of closed systems from which they
can escape, only as result of accidental rupture or breakdown
of the containers or system, or as a result of the abnormal
operation of the equipment with which the liquids or gases
are handled, processed, or used.
In which ignitable concentrations of flammable gases or
vapours normally are prevented by positive mechanical
ventilation but which may become hazardous as a result of
failure or abnormal operation of the ventilation equipment.
That is adjacent to a Class I Zone 1 location, from which
ignitable concentrations of flammable gases or vapours could
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.
Note: The Zone 2 classification usually includes locations
where volatile flammable liquids or flammable gases or
vapours are used but which would become hazardous only in
case of an accident or of some unusual operating condition.
Class I Zone 0, 1 and Zone 2 Locations
17

Material Groups for Class I Zones 0, 1 & 2
Group E
For mining, not covered by NEC
Group II
Subdivided into IIC, IIB & IIA for protection technique ‘d’
Group IIC
Atmospheres containing acetylene, hydrogen, or flammable
gas, flammable liquid produced vapour mixed with air that
may burn or explode, having either a max experimental
safe gap (MESG) value less than or equal to 0.50mm or min
igniting current ratio (MIC ratio) less than or equal to 0.45.
Material Groups
for Class I Zones 0, 1 & 2
Group IIB
Atmospheres containing acetaldehyde, ethylene, or flammable
gas, flammable liquid produced vapour, or combustible liquid
produced vapour mixed with air that may burn or explode
having either a max experimental safe gap (MESG) value
greater than 0.50mm and less than or equal to 0.90mm or
min igniting current ratio (MIC ratio) greater than 0.45 and
less than or equal to 0.80.
Group IIA
Atmospheres containing acetone, ammonia, ethyl alcohol,
gasoline, methane, propane, or flammable gas, flammable
liquid produced vapour mixed with air that may burn or
explode, having either a max experimental safe gap (MESG)
value greater than 0.90mm or min igniting current ratio (MIC
ratio) greater than 0.80.
MSEG
The maximum experimental safe gap of flammable gases
and vapours is the lowest value of the safe gap measured
according to 60079-1-1 by varying the composition of the
mixture (“flame propagation in the most incendive mixture”).
The safe gap is the gap width at which in the case of a given
mixture composition, a flashback just fails to occur.
MIC
The ratio derived by dividing the minimum current required
from an inductive spark discharge to ignite the most easily
ignitable mixture of a gas or vapor by the minimum current
required from an inductive spark discharge to ignite methane
under the same test conditions.
Atmospheres containing acetylene, hydrogen, or flammable
gas, flammable liquid produced vapour mixed with air that
may burn or explode, having either a max experimental
safe gap (MESG) value less than or equal to 0.50mm or min
igniting current ratio (MIC ratio) less than or equal to 0.45.
18

Protection Techniques
Class I Zone 1 or 2
Flameproof ‘d’
Type of protection where the enclosure will withstand an
internal explosion or flammable mixture that has penetrated
the interior.
Increased Safety ‘e’
Type of protection applied to electrical equipment that does
not produce arcs or sparks in normal service.
Wiring Methods
Class I Zone 1 or 2
Class I Zone 0
Intrinsically safe only
Class I Zone 1
As Class I Zone 0
MC-HL Cable
ITC-HL Cable
MI Cable
Rigid metallic conduit
Rigid non metallic conduit
Class I Zone 2
As Class I Zone 1
Threaded rigid metal conduit
Flexible metal conduit with listed fittings
Liquidtight flexible metallic conduit with listed fittings
Liquidtight flexible nonmetallic conduit with listed fittings
Zone 20, 21 and 22 Locations for Combustible Dusts,
Fibres and Flyings
Dust tight enclosures constructed so that dust will not enter
under specified test conditions.
Zone 20
An area where combustible dust or ignitable fibres and
flyings are present continuously or for long periods of time in
Zone 21
An area where combustible dust or ignitable fibres and flyings
are likely to exist occasionally under normal operation in
Zone 22
Area where combustible dust or ignitable fibres and flyings
are not likely to occur under normal operation in quantities
sufficient to be hazardous.
Wiring Methods
All Zones
Threaded rigid metal conduit
Liquid Tight metal conduit with listed fittings
Liquid Tight non metallic conduit with listed fittings
Wiring Methods
19

Wiring Methods
Location Wiring Methods Kopex-Ex Product Range
Class I • Threaded rigid conduit or threaded steel intermediate metal conduit HA Universal flameproof gland
Div 1 • Type MI cable with termination fittings with rigid conduit
CSA only • MC-HL cable for industrial establishments with restricted SP / TSP Stopping plugs
public access (other restrictions apply) Thread adaptors
• ITC-HL cable for industrial establishments with restricted
public access (other restrictions apply)
Class I All as for Class I Div 1 All range of HA glands
Div 2 • Type PLTC cable HA - G1 HA - U
• Type ITC cable HA - E HA - U/SW
• Type MI, MC, MV or TC cable SP / TSP Stopping plugs
• Flexible metal fittings Thread adaptors
• Flexible metallic conduit with listed fittings
• Liquid tight flexible metal
• Liquid tight flexible non-metallic conduit with listed fittings
Class II All as for Class II Div 1 All range of HA glands
Div 1 Threaded rigid conduit or threaded steel intermediate metal conduit HA - G1 HA - U
• Type MI cable with termination fittings HA - E HA - U/SW
• MC-HL cable for industrial establishments with restricted SP / TSP Stopping plugs
public access (other restrictions apply) Thread adaptors
• Dust tight flexible connectors
• Liquid tight flexible metal conduit with listed fittings
• Liquid tight flexible non-metallic conduit with listed fittings
Class III Rigid metal conduit, rigid non-metallic conduit, intermediate metal All range of HA glands
Div 1 conduit, electrical metallic tubing, dust tight wireways, HA - G1 HA - U
Type MC or MI cable HA - E HA - U/SW
• Liquid tight flexible metallic conduit with listed fittings SP / TSP Stopping plugs
• Liquid tight flexible non-metallic conduit with listed fittings Thread adaptors
Class III All as for Class II Div 1 All range of HA glands
Div 2 HA - G1 HA - U
HA - E HA - U/SW
SP / TSP Stopping plugs
Thread adaptors
Wiring Methods
Low Fire Hazard - Galvanised Steel Conduit Non-metallic - Overbraided Nylon Conduit
20

2.3 IECEx (International Scheme)
The IECEx scheme is an international certificate of
conformance for products used in a hazardous area.
This scheme provides:
a) A single certification of conformity for manufacturers to
comply that includes:
i) Testing and assessment of products to a standard
including a full test report.
ii) Ongoing surveillance of manufacturers premises.
b) A fast-track process for countries where regulations still
require the issuing of national Ex certificates or approvals.
This scheme is in the process of being adopted by all the
known standards across the world but are all working to
various time scales.
2.4 UL (America) & CSA (Canada)
The American and Canadian standards are the only ones to
have different classifications and locations. ATEX & IECEx
work to Groups and Zones whereas the NEC & CEC works
to Classes and Divisions, there is no direct comparison
between the two. This means that it is imperative that the two
standards are not inter-changed within an area.
2.5 GOST (Russia)
GOST follows similar rules to that of IECEx as far as the
breakdown of the zones and other criteria are concerned.
However, the requirements for this country mean that
separate GOST markings are required on the product.
GOST is divided into GOST (R) which is the standard for Russian
Federation and GOST (K) that cover Kazakhstan.
IECEx Kopex-Ex Products
Range Name ATEX Number Standard
Nylon conduit systems IECEx BAS08.0001X IEC60079-0:2006
Anti-static IEC60079-7:2007
IEC61241-0:2006
IEC61241-1:2004
Flameproof IECEx BAS06.0059X IEC60079-0:2004
Conduit glands IEC60079-1:2003
IEC60079-7:2001
IEC61241-0:2004
IEC61241-1:2004
Group I glands IECEx SIRA09.0103X IEC60079-0:2007-10 Ed5
G1, U, E IEC60079-1:2007
IEC60079-31:2008
IEC60079-7:2006
Thread convertors IECEx BAS07.0090X IEC60079-0:2006
Reducers IEC60079-1:2004
Enlargers IEC60079-7:2003
(+AmIECdmIECts)
IEC61241-0:2004
IEC61241-1:2004
Standard IECEx BAS08.0109X IEC60079-0:2004
stopping plugs IEC60079-1:2007
Tamperproof IECEx BAS08.0109X IEC60079-0:2004
Hex head IECEx BAS08.0108X IEC60079-0:2006
IEC61241-0:2004
IEC61241-1:2004
Dome head IECEx BAS08.0108X IEC60079-0:2006
IEC61241-0:2004
IEC61241-1:2004
Flexible - Stainless Steel Conduit
21

Section 3 - Equipment v Component
Within the ATEX and IECEx standard, hazardous area products
can be classified as Equipment Restricted, Equipment
Unrestricted or Components.
This is symbolised in the part marking by a character
immediately following the certificate number:
10ATEX1234 Equipment for use without restriction
10ATEX1234X Equipment for use under special
conditions or restrictions
(Outlined in certificate schedule)
10ATEX1234U Component not intended to be used alone
and requires additional certification (Partial certificate can
form basis for testing).
Section 3
Equipment v Component
Products certified as pieces of equipment can be used with
any other piece of certified equipment without the need
for product or installation testing. However products certified
as components will require further testing to confirm the
overall assembly or finished product complies with, and meets
the requirements of the ATEX standard.
Kopex-Ex Classifications
Product ATEX Classification Kopex-Ex Product Range
Non-metallic conduit system Equipment Conduit and Gland must be used together
HA - GI Barrier glands Equipment For Exe IP must be maintained upon installation
HA - U Universal glands Equipment For Exe IP must be maintained upon installation
HA - GII Barrier glands Equipment For Exe IP must be maintained upon installation
Thread Convertors Equipment For Exe IP must be maintained upon installation
SP Stopping plugs Equipment None
TSP Stopping plugs Equipment None
HSP Stopping plugs Equipment For Exe IP must be maintained upon installation
DSP Stopping plugs Equipment For Exe IP must be maintained upon installation
Couplers Component Must be certified in conjunction with useage
Section 3.1 - Kopex-Ex Classifications
HA - G1 Gland HSP / DSP Stopping Plug
22

Section 3 - Equipment v Component
Section 3.2 - UL / CSA Classifications
Unlike ATEX and IECEx, UL/CSA do not classify products as
Equipment or Component, instead they are simply ‘Listed’
for consumer use or ‘Recognised’ as approved components,
all Kopex-Ex Products are Listed products and can be used
straight away with the following limitations:
UL / CSA Classifications
Product UL / CSA HAZLOC Restrictions / Conditions
HA - GI Barrier glands Class I Div 2 Flexible conduit gland
HA - U Universal glands Class I Div 1 Rigid conduit only
Thread Convertors Class I Div 1 Plated Brass and
Stainless Steel only
SP Stopping plugs Class I Div 1 Plated Brass and
TSP Stopping plugs Class I Div 1 Plated Brass and
Stopping Plug Stainless Steel Thread ConverterPlated Brass Thread Converter
Stainless Steel Thread ConverterHA - U Universal Gland
UL / CSA Classifications
23

Section 4 - Cable v Conduit
The feeding of electrical and data cables around a hazardous
area is often complex and needs a great deal of thought. In
this section we will try to outline the decisions that need to be
taken, as well as pointing possible alternatives from Kopex-Ex.
4.1 Cable
If cable is the choice then there is a selection of many different
cables to choose from.
This can be further complicated by requirements of Exd which
requires cable to be:
• Substantially compact and circular cable.
• Extruded beading.
• Fillers which are Non-Hygroscopic.
Section 4
Cable v Conduit
The next thing to consider is the amount of cables required
and where they are terminating. For example if they are
terminating at the same control box then this may impact on
the size of the enclosure due to size limitations of the glanding
plate (See example below).
Exe ExdExe Exd
Exd Exe
24

4.2 Conduit
When applying conduit systems the cable limitations are
negated due to the fact that you can run cables through the
conduit system. This permits multi-cores to be run through the
same conduit so reducing the number of cable entries required
(See examples below).
This method can have a number of beneﬁts and selection
criteria can be greatly reduced due to the following:
• Is the application Exe or Exd?
• How many cables are required? This is needed to calculate
the cross sectional area of the cable to establish the
conduit size.
Advantages of Conduit systems:
• Easier termination of the cables.
• Reduced installation time.
• Greatly reduces the risk of the integrity of the enclosure
being compromised.
• Additional cables can be added without the need for
drilling more entries (Exe only).
• Potential to reduce the enclosure size.
• Minimise risk of damage through crushing.
• Potential to run power and data through one conduit
system (data needs to be screened).
• EMC can be obtained through the conduit.
• Use of SWA cable not required.
Exd Exe
Section 4 - Cable v Conduit
Conduit
25

Section 5 - Applications of Products
Section 5
Applications of Products
Applications of Products
Skids Control Boxes Motors Lighting
Liquid tight conduits systems Thread convertors Liquid tight conduit systems Thread convertors
Conduit glands Standard stopping plugs Conduit glands Standard stopping plugs
Thread convertors Tamperproof stopping plugs Thread convertors Tamperproof stopping plugs
Standard stopping plugs Standard stopping plugs
Tamperproof stopping plugs Tamperproof stopping plugs
Skids Control Boxes Motors Lighting
Nylon conduits systems Nylon conduits systems Nylon conduits systems Nylon conduits systems
Thread convertors Thread convertors Thread convertors Thread convertors
Hex head stopping plugs Hex head stopping plugs Hex head stopping plugs Hex head stopping plugs
Dome head stopping plugs Dome head stopping plugs Dome head stopping plugs Dome head stopping plugs
Nylon glands Nylon glands Nylon glands Nylon glands
Nylon stopping plugs Nylon stopping plugs Nylon stopping plugs Nylon stopping plugs
Exe ExdExe Exd
Exd
Exd
26

Section 6 - Product Features and Benefits
Section 6
Product Features and Benefits
Product Features and Benefits
Range Name Features Benefits
Nylon conduit systems Dual Certified ATEX / IECEx Highly flexible and high strength
Anti-static Braided versions available No requirement for double stocking
Reduces the amount of glanding
Allows for running of multi-core
Conduit glands Certified to ATEX, IECEx & CSA No requirement for retesting
Group I Mining applications installation options
G1, U, E High Temperature can be used with rigid conduit
Conduit glands Dual Certified ATEX / IECEx No requirement for retesting once installed
Group II Reduces the amount of glanding
Thread convertors Tested as Equipment No requirement for retesting once installed
Dual Certified ATEX / IECEx No requirement for double stocking
Full Identification marking No problems on site with inspections
Tested to the latest 60079 version Gives peace of mind once installed
Certified to UL Standard for Class I Div 1
Standard stopping plugs Tested as Equipment No requirement for retesting once installed
Dual Certified ATEX / IECEx Gives peace of mind once installed
Tested to the latest 60079 version
Tamperproof stopping plugs Tested as Equipment No requirement for retesting once installed
Dual Certified ATEX / IECEx Gives peace of mind once installed
Tested to the latest 60079 version
Hex head stopping plugs Tested as Equipment No requirement for retesting once installed
Dual Certified ATEX / IECEx IP rating guaranteed
Sealing washers and O rings supplied CW Gives peace of mind once installed
Dome head stopping plugs Tested as Equipment No requirement for retesting once installed
Dual Certified ATEX / IECEx IP rating guaranteed
Sealing washers and O rings supplied CW GIves peace of mind once installed
27

28
Section 7
Services We Offer
Section 7 - Services We Offer
Product / Standards Training
As a market leader we at Kopex Ex understand the
importance of product performance and application within
hazardous areas.
As a part of this commitment we have invested in and can
now offer Continuous Professional Development (CPD) courses
to consultants and installers alike.
These informative courses are designed to ﬁt into existing
CPD schemes run by various professional institutes. If
you would like to ﬁnd out additional details including where
courses are taking place and how to enroll please
register your details on our website:
www.kopex-ex.com
Alternatively you can e mail us at
marketing@kopex.co.uk
Design, Innovation and Advice
Exploiting its long and unrivalled experience in specialist
conduit systems for hazardous area applications, Kopex-Ex
provides a design and support service for its customers,
recommending the most appropriate product solution for any
application. Its team of Design and Technical Engineers can
provide innovative design solutions and advice.

Section 7 - Services We Offer
29
Installation Technical Advice
The Technical Support team can also advise on speciﬁc
installations to ensure that the best conduit solution is selected
for the application.
Joint Design Collaboration
As part of its design services, Kopex-Ex can work closely with
speciﬁers, end users and other suppliers of hazardous area
equipment and assemblies to ensure a fully integrated solution.
Advice on the Latest Standards
With changes in the legislation and directives Kopex-Ex can
help by offering assistance. Simply contact the company’s
Technical Support team by phone or email for prompt and up
to date advice.
Keeping you up to date
You can also receive up to date and instant product, standard and
application mail shots in addition to short form catalogues and
technical bulletins directly to your inbox.
Simply register your details on our website
at www.kopex-ex.com

30
Notes

31
3
Notes

Kopex International
UK Head Office
Station Road, Coleshill,
Birmingham, B46 1HT
T +44 (0) 1675 468 213
F +44 (0) 1675 468 280
I www.kopex-ex.com
The content of the Thomas & Betts catalogue has been carefully checked for accuracy at the time of print. However,
Thomas & Betts doesn’t give any warranty of any kind, express or implied, in this respect and shall not be liable for
any loss or damage that may result from any use or as a consequence of any inaccuracies in or any omissions from the
information which it may contain.
Copyright Thomas & Betts 2011. Copyright in these pages is owned by Thomas & Betts except where otherwise indicated.
No part of this publication may be reproduced, copied or transmitted in any form or by any means, without our prior
written permission. Images, trade marks, brands, designs and technology are also protected by other intellectual prop-
erty rights and may not be reproduced or appropriated in any manner without written permission of their respective
owners. Thomas & Betts reserves the right to change and improve any product specifications or other mentions in the
catalogue at its own discretion and at any time. These conditions of use are governed by the laws of the Netherlands and
the courts of Amsterdam shall have exclusive jurisdiction in any dispute.
From our UK based facility Kopex International manufactures a wide range of worldwide
approved products including metallic and non metallic conduit and fittings along with
a full range of conduit accessories, DIN rail terminals and non metallic cable glands.
Kopex is committed to an extensive and on going R&D programmme, which will
continue to deliver innovative and high performance products for safety critical areas.

Thomas & Betts Kopex - Understanding Hazardous Areas & Specifying Flexible Conduit

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