EU Directive 94/9/EC (ATEX 95) for Pneumatic Components

EU Directive 94/9/EC (ATEX 95)

for Pneumatic Components

EX-PROOF

ATEX (Atmosphères explosibles)

The abbreviation ATEX covers two European Union Directives: 94/9/EC and 1999/92/EC.

Potentially explosiveatmospheres

Explosions can alwaysoccur where combustiblegases, vapours, liquids ordusts are produced, storedor transported and canunder certain conditionscombine with air to forman explosive mixture. Insuch potentially explosiveatmospheres a small sparkis often enough to triggeran explosion. Potentiallyexplosive atmospheresoccur for example inchemical plants, refineries,tank installations, paintfactories and other placeswhere dust-forming bulkgoods are processed ortransported, e.g. in flourmills, animal feed factoriesand cement works.

What are potentialignition sources?

Electrical ignition sourcescan be:– Arcing when contacts are

opened– Transient electric currents– Electrostatic discharge– Hot surfaces on coils

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Pneumatic Components in -AtmospheresATEX 95 and ATEX 137

Directive 94/9/EC isdesigned to harmonize thelaws of the EU MemberStates concerning equip-ment and protectivesystems intended for use inpotentially explosiveatmospheres.Previously known as ATEX100a, the Directive now hasthe working title ATEX 95and defines the unifiedsafety requirements neededfor free trade.The Directive has beenincorporated into the

national law of the MemberStates and applies to thesales of equipment,components and protectivesystems for use inpotentially explosiveatmospheres with effectfrom 1st July 2003.Therefore this Directivemainly affects themanufacturer.Directive 1999/92/ECdefines the minimumrequirements for theimprovement of the healthprotection and safety of

employees who may beendangered by explosiveatmospheres.It was previously known asATEX 118a and is nowcalled ATEX 137.This Directive applies tooperators of plant with ex-plosive atmospheres andapplies to the building ofnew plant, also with effectfrom 1st July 2003.For the adaptation of existingplant there is a transitionalphase up to 31st December2005.

Examples of mechanicalignition sources:– Hot surfaces caused by

friction– Adiabatic compression– Sparks created by

impactsExamples of other ignitionsources:– Open fire– Hot-running bearings– Auto-ignition– Lightning strike

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The application of ATEXhas basically made thefollowing changes:– The Directive now also

applies to non-electricalequipment (e.g. pneu-matic drives) as well asto electrical equipment.

– It defines fundamentalsafety requirements andalso applies to completeprotective systems.

– Equipment is divided intoGroups and Categories.These are then related tocorresponding danger

All electrical equipment foruse in potentially explosiveatmospheres was alreadycovered by the existing lawon explosion protection.ATEX 95 howeveradditionally applies to non-

Application of ATEX to Manufacturers and Operators

With effect from 1st July 2003 the responsibility for newly built plant with potentially ex-plosive atmospheres lies not only with the manufacturer of explosion-proof equipmentbut also with the operator and builder of the plant.

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Zones which have to bedefined by the operatorin accordance withATEX 137.

– Depending on the Equip-ment Category, a typeapproval is required.

– Marking with the CEmark is now compulsory.

– A declaration of con-formity must accompanyeach product as well asthe operating instruc-tions.

electrical equipment, suchas piston rod cylinders,rodless cylinders andvalves.It therefore applies to allequipment for use inpotentially explosive

atmospheres which haveany intrinsic potentialsource of ignition, includingsources such as hotsurfaces or adiabaticcompression.

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The following productexamples have no intrinsicsources of ignition andtherefore do not fall underATEX 95.

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– Pneumatic accessories– Mechanical accessories– Tubing– Fittings– Check/ flow control

valves

Such products can be usedin specified potentiallyexplosive atmospheres inaccordance with themanufacturer’s instructions.

– The Directive now alsoapplies to potential dustexplosion atmospheres.

– It now applies to under-ground mining opera-tions as well as to allother potentially explosiveatmospheres.

Application to Manufacturers and Operators

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ATEX 95 for the Manufacturer

Under ATEX 95 the manufacturer has to evaluate his products and to mark themaccordingly:

- Division into Equipment Groups and Categories for use in different Zones- Division into Temperature Classes

- Division into Explosion Groups- Determination of permissible ambient temperatures

The Equipment Groups and Categories are defined as follows. You will findfurther information on the Temperature Classes and Explosion Groups on

page 7.

Equipment Group IEquipment in Group I is divided into Categories M1 and M2.

This equipment is used in mining, where there is the danger of explosions causedby firedamp or flammable dust.

HOERBIGER-ORIGA do not manufacture Group I Equipment

Equipment Group IIEquipment in Group II is divided into Categories 1, 2 and 3 according to its suitability foruse in the different Zones defined by ATEX 137.

Pneumatic Components in -AtmospheresATEX for Manufacturers and Operators

Category 1This equipment is designedto ensure a very high levelof safety. It must ensure therequired level of safetyeven in the event of rareequipment malfunctions.Therefore its explosionprotection system mustensure that:– in the event of the failure

of one means of protec-tion, at least one second,independent meansprovides the requiredlevel of protection

– or in the event of twofaults occurringindependently of eachother, the required levelof safety is still ensured.

Category 2This equipment is designedto ensure a high level ofsafety. Its explosionprotection system mustensure the required level ofsafety even in the event offrequently occurringincidents or equipmentmalfunctions whichnormally have to beexpected.

Category 3This equipment is designedto ensure a normal level ofsafety so that it providesthe requisite level of safetyin normal operation.

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ATEX 137 for the Operator

Under ATEX 137 the operator must assess his plant, identify dangers, evaluate the risks(e.g. within the framework of an explosion protection document) and define appropriateprotective measures:– Division of the plant into Zones according to the assessed danger potential– Determination of Temperature Classes– Determination of Explosion Groups– Determination of ambient temperatures experienced

The Zones are defined under ATEX 137 as follows. You will find further informationon the Temperature Classes and Explosion Groups on page 7.

Allocation of Equipment Groups and Categories to Zones

Zone 0 (Gases)An area in which an explo-sive atmosphere occurs asa mixture of air andflammable gases, vapoursor mists constantly,frequently or for longperiods. Such conditionsare found for exampleinside storage tanks orpipework.

Zone 1 (Gases)An area in which an explo-sive atmosphere can occuras a mixture of air andflammable gases, vapoursor mists occasionally. Suchareas can be for example inclose proximity to a Zone 0or to filling and emptyingequipment.

Zone 2 (Gases)An area in which an explo-sive atmosphere as amixture of air andflammable gases, vapoursor mists does not normallyoccur in normal operation,or occurs only briefly. Suchareas might be for examplenear a Zone 1, nearpipework connections or instorage areas.

Zone 20 (Dusts)An area in which an explo-sive atmosphere occurs asa dust cloud or dust layerconsisting of air andflammable dust particlesconstantly, frequently or forlong periods.

Zone 21(Dusts)An area inwhich anexplosiveatmospherecan occur as a dust cloudor dust layer consisting ofair and flammable dustparticles occasionally innormal operation.

Zone 22 (Dusts)An area in which an explo-sive atmosphere as a dustcloud or dust layerconsisting of air andflammable dust particlesdoes not normally occur innormal operation, oroccurs only briefly.

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Equipment in Potentially Explosive Atmospheres Intrinsic Safety, Encapsulation

Intrinsically SafeEquipmentIntrinsically safe equipmentis equipment in which allthe circuits are intrinsicallysafe (in conformity withEN 50020).

Protection Type„Intrinsic Safety“Intrinsic safety is basically atechnology in which verylow power consumption isused. It is thereforeespecially suitable forindustrial instrumentation.

Intrinsically Safe CircuitsAn intrinsically safe circuitis a electric circuit, in whichneither a spark still anotherthermal effect can cause anignition of a certain explo-sive atmosphere.

Intrinsic Safety „i“Intrinsic safety is one ofseveral usual methods ofavoiding explosions inpotentially explosiveatmospheres.In contrast to other types ofprotection, „intrinsic safety“relates not only to individu-al components but to thewhole circuit which isintrinsically safe.The protection here lies inthe circuit and not indesign features such ashousings or encapsulation.Intrinsically safe equipment/ circuits operate with verylow electrical energy whichis insufficient to ignite eventhe most flammableatmospheres mixtures.

For this reason there can beno spark creation or ther-mal effect in intrinsicallysafe circuits, i.e. ignition ofthe explosive atmospherecannot occur.Two different ignitionmechanisms are taken intoaccount:– ignition by electric sparks– ignition by surfacesheated by current.The potentially explosiveatmosphere can includevarious flammablesubstances such as gases,vapours, dust, fibres andairborne particles.Therefore the circuits andequipment are so designedthat safety is guaranteednot only in normaloperation but also in allpossible failure conditions.

Types of Protection

Protection Type„Encapsulation“““““

Encapsulation „m“In encapsulation, possibleignition sources in electricalequipment are enclosed ina casting compound, sothat the ignition of apotentially explosiveatmosphere is impossible.

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Conditions for trouble-freeoperation and also failureconditions are fixed in thestandard EN 50020.

Anwendung der ATEX durch Hersteller und Betreiber

7

Type Marking of Equipment for Use in -Atmospheres

Examples of type markings:Mechanical equipment: II 2 GD c T4 T135°C -10°C≤Ta≤+60°CElectrical equipment: II 2 GD E Ex ib IIC T5 T100°C -20°C≤Ta≤+75°C IP65

Pneumatic Components in -AtmospheresType Marking of Equipment

Mechanical Electrical DescriptionEquipment Equipment

Ex mark. Approved for use in potentially explosive atmospheresCE mark

II II Equipment Group I Use in miningII Use in all other Ex-atmospheres

2GD 2GD Equipment Category G = gas, D = dust2G Use in Zone 12GD Use in Zone 213G Use in Zone 23GD Use in Zone 22

E Equipment is approved to the CENELEC European StandardEx Equipment is explosion-proof

c ib Type of ignition protection ia Intrinsically safe, in normal operation will notcause ignition in the event of 1 or 2 faults inthe unit

ib Intrinsically safe, in normal operation will notcause ignition in the event of 1 fault in the unit

b Ignition source monitoring k Liquid encapsulationc Safe design m Cast encapsulationd Pressure-tight encapsulation o Oil encapsulatione Enhanced safety p Overpressure encapsulationfr Vapour-inhibiting encapsulation q Sand encapsulation

IIC Explosion Group Different gases have different ignitability:Group Typical gas Minimum

(example) ignition energyIIA Propane 180 µJIIB Ethylene 60 µJIIC Hydrogen, acetylene 20 µJ

T4 T5 Temperature Class Highest permissible surface temperature for use in(Gas) gas-explosion-protected atmospheres

^T-class Max. surface Min. ignition

temperature temperatureof the gasT1 450°C > 450°CT2 300°C > 300°C bis ≤ 450°CT3 200°C > 200°C bis ≤ 300°CT4 135°C > 135°C bis ≤ 200°CT5 100°C > 100°C bis ≤ 135°CT6 85°C > 85°C bis ≤ 100°C

T135°C T100°C Maximum surface temperature for use in dust-explosion-protected atmospheres.If no Temperature Class is specified (e.g. T5), this value also applies to gas-explosion-protected atmospheres

-10°C≤Ta≤+60°C -20°C≤Ta≤+75°C Permissible temperature range for the use of the equipment in explosion-protectedatmospheres

IP65 Housing protection system for electrical equipment (e.g. IP65 = dust-tight andwater-jet-proof from all directions)

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Pneumatic Components in -AtmospheresHOERBIGER-ORIGA Products

HOERBIGER-ORIGA Products for -Atmospheres

Equipment Group II Category 2GD

Piston Rod Cylinders: II 2GD c T4 T135°C –10°C≤Ta≤+60°C

Series Size Stroke Range Accessories IllustrationAZ Series 5000 Ø32 – 100 1 – 2000 mm Mountings programme,

FEUG/FEHG/FEHK

DZ Series 5000 Ø125 – 250 10 – 2000 mm Mountings programme,

NZK Series 6000 Ø32 – 100 1 – 500 mm Mountings programme,FEUG/FEHG/FEHK

NZK Series 7000 Ø32 – 100 1 – 25 mm Mountings programme,FEUG/FEHG/FEHK

R Series 6000 Ø10 – 25 1 – 500 mm Mountings programme, FEUG

R Series 5000 Ø20 – 25 1 – 500 mm Mountings programme, FEUG

SZ Series 6000 Ø12 – 100 1 – 80 mm Mountings programme

SZ Series 7000 Ø32 – 100 1 – 25 mm Mountings programme

Magnetic S Magnetic S Magnetic S Magnetic S Magnetic Switwitwitwitwitches:ches:ches:ches:ches:

RS-K ATEX, cable length 5m II 3GD EEx nC IIC T3 T146°C –25°C II 3GD EEx nC IIC T3 T146°C –25°C II 3GD EEx nC IIC T3 T146°C –25°C II 3GD EEx nC IIC T3 T146°C –25°C II 3GD EEx nC IIC T3 T146°C –25°C≤TTTTTaaaaa≤+80°C+80°C+80°C+80°C+80°CRS-K ATEX, cable length 10m II 3GD EEx nC IIC T3 T146°C –25°C II 3GD EEx nC IIC T3 T146°C –25°C II 3GD EEx nC IIC T3 T146°C –25°C II 3GD EEx nC IIC T3 T146°C –25°C II 3GD EEx nC IIC T3 T146°C –25°C≤TTTTTaaaaa≤+80°C+80°C+80°C+80°C+80°C

ES-K ATEX, cable length 5m II 2GD EEx ib IIC T5 T100°C –20°C II 2GD EEx ib IIC T5 T100°C –20°C II 2GD EEx ib IIC T5 T100°C –20°C II 2GD EEx ib IIC T5 T100°C –20°C II 2GD EEx ib IIC T5 T100°C –20°C≤TTTTTaaaaa≤+75°C+75°C+75°C+75°C+75°CES-K ATEX, cable length 10m II 2GD EEx ib IIC T5 T100°C –20°C II 2GD EEx ib IIC T5 T100°C –20°C II 2GD EEx ib IIC T5 T100°C –20°C II 2GD EEx ib IIC T5 T100°C –20°C II 2GD EEx ib IIC T5 T100°C –20°C≤TTTTTaaaaa≤+75°C+75°C+75°C+75°C+75°C

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S9 For dust-EX-atmospheres see page 13


9

Equipment Group II Category 2G

Rodless Cylinders: II 2G c T4 T135°C –10°C≤Ta≤+60°C

Series Size Stroke Range Accessories Illustration

OSP-P Ø10 – 80 1 – 6000 mm Mountings programme

Slideline Ø16 – 80 1 – 6000 mm

Valves: II 2G c T4 T135°C –10°C≤Ta≤+60°C

Series Size Accessories Illustration

S9 pneumatically G1/8, G1/4, G1/2 P-/RPS-manifoldsactuated

S9 manually G1/8, G1/4, G1/2 P-/RPS-manifoldsactuated

S9 electrically G1/8, G1/4, G1/2 P-/RPS-manifoldsactuated

Solenoids Category of Solenoid Comments

GS24V-3m-ATEX II 2G EEx m II T5 -20°C≤Ta≤+50°C Individual use



GS24V-1,2m-ATEX II 2G EEx m II T5 -20°C≤Ta≤+50°C Individual use

WS230V-3m-ATEX II 2G EEx m II T5 -20°C≤Ta≤+50°C Individual use

WS230V-1,2m-ATEX II 2G EEx m II T5 -20°C≤Ta≤+50°C Individual use



Ambienttemperature II 2G EEx m II T5 -20°C≤Ta≤+40°C Manifold mounting

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Equipment Group II Category 2GAir Preparation Equipment: II 2G c II B X - Use in Zone 1, 2


Filter-regulators G1/4MFRSairfit light

Pressure regulators G1/8, G1/4 Pressure gauges, mountings,MRS couplings

airfit swingShut-off valves G1/4, G3/8 Mountings, couplings, lockSDV

Filter-regulators G1/4, G3/8 Pressure gauges, mountings,SK couplings

Filter-water-separators G1/4, G3/8 Mountings, couplingsSF

Pressure regulators G1/4, G3/8 Pressure gauges, mountings,SR couplings

Pressure regulators G1/4, G3/8 Pressure gauges, mountings,with through-p1 couplingsSR-..T-

Oil mist lubricators G1/4, G3/8 Mountings, couplingsSL

Pressure regulators, G1/4, G3/8 Pressure gauges, mountings,pilot-operated couplingsSRV

Submicrofilters G1/4, G3/8 Mountings, couplingsMF012

Activated carbon filters G1/4, G3/8 Mountings, couplingsMC012

Soft start valves G1/4, G3/8 Mountings, couplingsSDA

Stop valves G1/4, G3/8 Mountings, couplingsSDR-PSDR-E ( II 2G EEx m II T5)

Equipment Group IIPneumatic Accessories: Use in Zone 1, 2, 21, 22

Check & flow control valvesLogic valvesFittingsTubing


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airfit comfortShut-off valves G3/8, G1/2 Mountings, couplings, lockCDV

Filter-water-separators G3/8, G1/2 Mountings, couplingsCF

Dust filter G3/8, G1/2 Mountings, couplingsCFD

Filter-regulators G3/8, G1/2 Pressure gauge, mountings,CK couplings

Pressure regulators G3/8, G1/2 Pressure gauge, mountings,CR couplings

Pressure regulators G3/8, G1/2 Pressure gauge, mountings,with through-p1 couplingsCR-..T-

Pressure regulators, G3/8, G1/2 Pressure gauge, mountings,pilot-operated couplingsCRV

Oil mist lubricators G3/8, G1/2 Mountings, couplingsCL

Submicrofilters G3/8, G1/2 Mountings, couplingsMF036

Activated carbon filters G3/8, G1/2 Mountings, couplingsMC036

Soft start valves G3/8, G1/2 Mountings, couplingsCDA

Stop valves G3/8, G1/2 Mountings, couplingsCDR, CDR-P,CDR-E ( II 2G EEx m II T5)

airfit prestigeShut-off valves G3/4, G1 Mountings, couplings, lockXDV

Filter-regulators G3/4, G1 Pressure gauge, mountings,XK couplings

Filter-water-separators G3/4, G1 Mountings, couplingsXF

Dust filters G3/4, G1 Mountings, couplingsXFD

Pressure regulators G3/4, G1 Pressure gauge, mountings,XR couplings

Pressure regulators G3/4, G1 Pressure gauge, mountings,pilot-operated couplingsXRV

discontinueddiscontinueddiscontinueddiscontinueddiscontinued






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airfit prestigeOil mist lubricators G3/4, G1 Mountings, couplingsXL

Submicrofilters G3/4, G1 Mountings, couplingsMF110, MF185

Activated carbon filters G3/4, G1 Mountings, couplingsMC110, MC185

Start/stop valves G3/4, G1 Mountings, couplingsXDS

airfit A25Shut-off valves G3/4, G1 Mountings, couplingsA25DV

Filter-regulators G3/4, G1 Pressure gauge, mountings,A25K couplings

Filter-water-separators G3/4, G1 Mountings, couplingsA25F

Dust filters G3/4, G1 Mountings, couplingsA25FD

Pressure regulators G3/4, G1 Pressure gauge, mountings,A25R couplings

Pressure regulators G3/4, G1 Pressure gauge, mountings,pilot-operated couplingsA25RV

Oil mist lubricators G3/4, G1 Mountings, couplingsA25L

Submicrofilters G3/4, G1 Mountings, couplingsA25MF

Activated carbon filters G3/4, G1 Mountings, couplingsA25MC

Start/stop valves G3/4, G1 Mountings, couplingsA25DS

airfit A50Filter-water-separators G11/2, G2 Mountings, couplingsA50F

Pressure regulators G11/2, G2 Pressure gauge, mountings,A50R couplings

Submicrofilters G11/2, G2 Mountings, couplingsA50MF

Activated carbon filters G11/2, G2 Mountings, couplingsA50MC

Start/stop valves G11/2, G2 Mountings, couplingsA50DS

airfit dryMembrane dryers G1/4, G1/2, G1 Mountings, couplingsSDM, CDM, XDM







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HOERBIGER-ORIGA Products for -Atmospheres „Intrinsic Safety “


Valves: II 1G EEx ia IIC T4/T5/T6

Series Size Accessories IllustrationP8 385 Flange on request


Valves: II 2G EEx ia IIC T4/T5/T6Valves: II 2D Ex ia D21 T125


P8 385 Flange P-manifolds M5M5 RPS-manifolds M5


Valves: II 2G EEx ia IIC T4/T5/T6


P20 381 Flange to CNOMO P-manifolds G1/8G1/8 RPS-manifolds G1/8

Equipment Group I Category MI

Valves: I M1 EEx ia I

Series Size Accessories IllustrationP8 385 Flange


Valves: II 2GD EEx c IIC T5/T6 TFR:03.41X (for use 2D-T125)

Series Size Accessories IllustrationS9 385 G1/8 P-manifoldsS9 585 RPS-manifolds

S9 385 G1/4 P-manifoldsS9 585 RPS-manifolds

S29 385 NAMURS29 585 Output G1/4

On ROn ROn ROn ROn Requestequestequestequestequest

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Pneumatic Components in -AtmospheresDefinitions according to Directive 94/9/EC

Definitions according to Directive 94/9/EC

EquipmentEquipment meansmachines, apparatus, fixedor mobile devices, controlcomponents andinstrumentation thereof anddetection or preventionsystems which, separatelyor jointly, are intended forthe generation, transfer,storage, measurement,control and conversion ofenergy for the processingof material and which arecapable of causing anexplosion through theirown potential sources ofignition.

Protective SystemsProtective systems are alldevices with the exceptionof the components of theequipment defined abovewhich are designed to haltincipient explosionsimmediately and/or to limitthe area affected by theexplosion. They aremarketed separately asautonomous systems.

ComponentsComponents are itemswhich are essential for thesafe operation ofequipment and protectivesystems but which fulfil noautonomous function.

Explosive AtmosphereA mixture of air andflammable gases, vapours,mists or dusts underatmospheric conditions inwhich, after ignition hasoccurred, the combustionprocess spreads to theentire unburnt mixture.

Equipment Groups andCategoriesThe Equipment Groups andCategories define the levelof protection of a piece ofequipment and thus itspermissible use in poten-tially explosive atmosphe-res. You will find furtherinformation on page 4.

Potentially ExplosiveAtmosphereAn atmosphere whichcould become explosivedue to local andoperational conditions.

Intended UseThe use of equipment,protective systems anddevices in accordance withthe Equipment Group andCategory and incompliance with all themanufacturer’s informationrequired for the safeoperation of the products.

ZonesUnder Directive 1999/92/EC, potentially explosiveatmospheres must bedivided into Zones (Zones0, 1, 2), in accordance withthe requirements for safeoperation of explosion-proof equipment in theseatmospheres.You will find furtherinformation on page 5.


15

ATEX: Incorporation into National Law

Directives for the US Market

In the USA, potentially ex-plosive atmospheres aredivided into two Divisionsand combustible materialsare divided into threeClasses. In NEC Article 505the ATEX requirements forZones 0, 1 and 2 weretaken over for Class I.The following table showsa comparison of theclassification of potentiallyexplosive atmospheresaccording to the US andEuropean Directives.

Division 1Division 1Division 1Division 1Division 1An explosive atmosphereexists constantly, for longperiods or occasionally.

Division 2Division 2Division 2Division 2Division 2An explosive atmosphereexists only seldom orbriefly.

Class IClass IClass IClass IClass ICombustible gases,vapours and liquids.

Class IIClass IIClass IIClass IIClass IICombustible dusts.

Class IIIClass IIIClass IIIClass IIIClass IIISlightly combustibleparticles and materials.

Incorporation of ATEX into the National Lawof the EU Member States

All European Directiveshave to be incorporatedinto the national law of theEU Member States. InGermany the Directive94/9/EG was incorporatedinto law by the 11thOrdinance of theEquipment Safety Statute(Explosion ProtectionOrdinance - 11. GSGV) of12th December 1996.

The Directive 1999/92/EGwas incorporated intoGerman law by theOrdinance on Safety andHealth Protection in theConstruction and Operationof Equipment, Safety in theOperation of EquipmentRequiring Monitoring, and

Organisation of OperationalWork Protection (OperatingSafety Ordinance -BetrSichV) of27th September 2002.

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A5P060E-December 2004 A5P061E61LAE20X

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EU Directive 94/9/EC (ATEX 95) for Pneumatic Components

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