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Cooper Crouse-Hinds Ex Digest Flameproof Enclosures

CHAPTER 7 FLAMEPROOF ENCLOSURES

Field drilling of flameproof, Ex-d, enclosures is not allowed. To maintain the IEC or CENELEC certificate, these enclosures can only be modified by the manufacturer.

Flat machine joints are not allowed for Group A and B gases with explosionproof or for IIC gases with flameproof. Manufacturers use threaded or spigot joints for Groups A, B or IIC certifications.
Flamepath Gap Flamepath

7.1 EXPLOSIONPROOF VS FLAMEPROOF

The key points in comparing and explaining the installation of flameproof and explosionproof enclosures include the design, temperature rise, drilling of cable entry holes, approvals and certifications, joints or flamepaths and standards. The protection concepts behind both concepts are the same. Explosionproof enclosures are used more often as a method of protection in North America. Flameproof protection is used on projects with IEC standards. In most cases, both explosionproof and flameproof enclosures are constructed of metal to ensure adequate strength to withstand the internal forces of an explosion. The enclosures machined or threaded joints cool the escaping gases so they will not ignite the volatile gases in the hazardous area. Flameproof enclosures are individually tested at the factory at 1.5 times the maximum pressures exerted in an explosion. Explosionproof enclosures are tested at 4 times the maximum pressures exerted in an explosion. Because of this, explosionproof enclosures tend to have a heavier construction. Both explosionproof and flameproof covers are either bolted on or secured with threaded covers or joints. Flameproof enclosures are secured with special devices to prevent their removal without special tools.
Flamepath Flat joints (left) are used for IIA and IIB gases. Spigot joints (right) or threaded joints (not shown) allow manufacturers to obtain Groups A, B or IIC certifications.

Wiring room in flameproof enclosures is not a design consideration. The major constraint in the explosionproof enclosures is the internal wiring room and bending radius of the cables. As a result, flameproof enclosures may contain many more components inside than explosionproof enclosures. Flameproof enclosures cannot be field drilled. The manufacturer must drill entries into the enclosures. Explosionproof enclosures can be field drilled making their use more accommodating by OEMs

Entries into Ex-d enclosures must be drilled and tapped by the manufacturer.

Explosionproof enclosures can be field drilled.

Table 7.1 Summary of Differences Between Explosionproof and Flameproof CONSIDERATION Field Drilling Pressure testing Construction Joints Heat rise Wiring room Entries EXPLOSIONPROOF Acceptable 4 times maximum Heavier Threaded, flat, labyrinth (serrated) Not a consideration Major design consideration Field or factory drilled directly into enclosure FLAMEPROOF Must be drilled by manufacturer 1.5 times maximum Lighter Threaded, flat, spigot Factor which limits components inside Not a major design consideration Factory drilled directly into enclosure or field drilled into an Ex-e enclosure (indirect entry)

Cooper Crouse-Hinds Ex Digest Flameproof Enclosures 7.2 FLAMEPROOF ENCLOSURES

A flameproof Ex-d type enclosure is designed and tested to contain an explosion. Potentially explosive gas/air mixtures can be present inside a flameproof enclosure due to the heating and cooling cycle of electrical equipment use. An airborne gas/air mixture can be sucked in and expelled as the temperature changes. If the gas/air mixture inside the enclosure is between the Upper and Lower Flammable Limits (see 2.3.1) and a spark ignites the mixture, an explosion will occur.

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Installation procedures recommend that flameproof enclosures have a minimum distance from an obstructions to allow gases to further cool. This minimum distance differs according to gas group. Table 7.2 Minimum Distance From Obstructions Gas Group IIA IIB IIC Distance 10 mm 30 mm 40 mm

Additionally, the covers or lids of Ex-d enclosures must have devices to prevent entry unless special tools are used. Allen head screws are normally used to secure a fixed cover. Hex head set screw for locking cover

External ground lug

Covers on Ex-d enclosures must be secured so they can only be removed with special tools. The Ex-d flameproof junction box from the Cooper CrouseHinds, Nortem facility in Spain has a hex-head cover locking screw, external ground and thread openings for conduit or cable. 1. Temperature changes can suck gas/air mixtures into the enclosure 2. When the gas/air mixture is between the the Upper and Lower Flammable Limits and a spark occurs, ignition and an internal explosion can occur. 3. The hot compressed gases are forced out through the flamepath, but must not ignite any surrounding external potentially explosive atmosphere. The flamepath cools the hot, compressed gases as they are expelled, preventing any explosions of external atmospheres.

Components not suitable for installation in Ex-d enclosures are rewireable fuses, devices causing turbulence, oil filled contactors, components containing flammable liquids, liquids or material capable of releasing hydrogen, primary/secondary cells (possible hydrogen release).

All internal components in the Ex-d enclosure must have a clearance of at least 12 mm from the internal enclosure wall. In addition, obstructions adjacent to the external flamepath can cause pressure piling which results in an abnormally high explosion pressure.

Maintain minimum distances from obstructions

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Cooper Crouse-Hinds Ex Digest Flameproof Enclosures

The pressure inside a flameproof enclosure during an internal explosion can rise to 150 PSI (10 bar). There is also the possibility of pressure piling and detonation due to secondary ignition of compressed gases inside an enclosure, that can result in pressures of 450 PSI (30 bar). Pressure piling is the increase in explosion pressure above normal expected pressures caused by the ignition of a precompressed gas. This can result from modifications such as internal sub division of the flameproof enclosure or external obstruction adjacent to the flamepath. The static pressure tests requirement for flameproof enclosures are 10 bar for IIA and IIB Gas, 15 bar for IIC Gases. Flat joints can only be used with IIA and IIB gases. Threaded or spigot joints are normally used for gas group IIC applications because of the close tolerance and length of flamepath formed by the thread. The minimum number of thread engagements is not less than 5. The depth of engagement for up 100 cubic cm is 5 mm and above 100 cubic cm not less than 8 mm. The minimum width of joint and maximum gap relative to gas groups and the enclosure volume are detailed in Table 7.2.1.

7.2.1 FLAMEPATHS & JOINTS IIB VS IIC

All flameproof joints on enclosure covers or between compartments must be made by one of the following methods: Flat Joint Spigot joint Threaded joint A combination of all three It is assumed that flammable gases and vapors in the surrounding atmosphere can enter the flameproof enclosure by thermal cycling or breathing. A flameproof enclosure is built to withstand the pressure developed during an internal explosion following ignition without damaging the enclosure. In addition to withstanding an internal explosion, the flamepath width and gap in a flameproof enclosure must cool the hot flaming gases as they pass through the flamepath to prevent ignition of any surrounding explosive atmosphere. The major difference between the explosionproof enclosures used in North America and the flameproof enclosures used in IEC type installations is the construction method. Explosionproof enclosures are hydrostatically tested at 4 times the maximum pressure obtained during explosion tests. If each flameproof enclosure is tested before it leaves the factory, called a routine test, it can be constructed to only 1.5 times the maximum pressure. Because of the difference in testing, Ex-d enclosures may have lighter construction and the joints may not be as wide as those on explosionproof enclosures.

Table 7.2.1 Minimum width of joint and maximum gap for enclosures relative to Gas Groups Gas Group Min. Joint Width (mm) 6 9.5 12.5 25 II A 6 9.5 12.5 25 IIB 6 9.5 12.5 25 IIC 0 9.5 Maximum Gap for Enclosures with Volume > 100 cm3 > 500 cm3 > 2000 cm 3 3 3 500 cm 2000 cm 0.35 0.4 0.5 0.3 0.3 0.4 0.2 0.2 0.2 0.1 0.4 0.5 0.3 0.4 0.2 0.2 0.4 0.5 0.2 0.4 0.15 0.2

100 cm3 0.3 0.35 0.4 0.5 0.3 0.3 0.3 0.4 0.2 0.2 0.2 0.2 0.1 0.1

Cooper Crouse-Hinds Ex Digest Flameproof Enclosures 7.3 ENTRIES TO FLAMEPROOF ENCLOSURES

Field drilling of explosionproof enclosures is a task which requires a great deal of care, but is an acceptable practice in North America. This is especially welcomed by OEMs, which may need to modify enclosures in their certified shop to meet local wiring practices. Field drilling of flameproof, Ex-d, boxes is not allowed. To maintain the IEC certificate, these enclosures can only modified by the manufacturer. For installers or OEMs who may need to have additional entries in flameproof enclosures, it is recommended to order the flameproof enclosure with extra plugged holes or use the indirect entry method.

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terminations are made to terminal blocks. Field drilling into the Ex-e enclosure is allowed. Outside of Europe the concept of indirect entry is not widely practiced. Entries to the enclosures are made with Ex-d barrier glands, which are sealed cable glands. Many cable gland manufacturers now have dual Ex-d and Ex-e combined certification for their cable gland products.

7.3.1 INDIRECT CABLE ENTRY

In many European countries, entries to Ex-d boxes are made via Indirect Entry. This is a factory-sealed bushing located between the Ex-d and Ex-e increased safety enclosure where

Crouse-Hinds supplies Universal (Ex-d and Ex-e) glands which are marine rated and can be used for any metal clad cable.

Figure 7.31 Cabe Entry Techniques Ex-d flameproof enclosure

Factory sealed bushing

Ex-d gland

Sealing Fitting

Ex-e increased safety enclosure

Indirect wiring is required for entry into flameproof enclosures in Germany. Often referred to as factory sealing, it has been used for many years in Cooper Crouse-Hinds panel boards. (left to right) Factory sealed, indirect entry into Ex-e enclosures Ex-d cable gland directly into Ex-d enclosure Sealed conduit directly into Ex-d enclosures

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Cooper Crouse-Hinds Ex Digest Flameproof Enclosures 7.3.3 CABLE GLANDS

The correct selection of a cable gland is essential if the Ex Protection integrity of the apparatus being installed is to be maintained. Before considering whether the selected cable gland should be an appropriate standard version or an Ex-d barrier type it is important to consider the following specification requirements. 1. Type of Ex Protection required. 2. Direct or Indirect Entry 3. The cable type 4. Environmental conditions for the installation (gland material and finish) 5. Armor or Nonarmored cable. 6. Wire or Braided Armor. (W = Single wire, X = Braided, Y = Tape armor) 7. Cable inner and outer dimensions (Compare to gland manufacturers chart) 8. Apparatus entry thread type (ISO. PG, Taper, Pg) 9. Earth / Ground requirements (Consider prospective fault current) 10. Gas Group 11. Zone Classification 12. Ingress Protection 13. Water Deluge protection? 14. Sealing of threaded entry To select a suitable cable gland i.e. Standard d version or a Barrier type d gland, reference to the selection details below can assist with this process. Direct Entry Ex-d IIC apparatus in Zones 1 or 2 Ex-d barrier gland mandatory Direct Entry Ex-d IIC apparatus in Zones 1 or 2 and greater than 2 liters in volume. Ex-d barrier gland required Direct Entry Ex-d IIA and IIB apparatus in Zone 1 and less than 2 liters in volume. Standard Ex-d gland required Direct Entry Ex-d IIA and IIB apparatus in Zone 2. Standard Exd required
4. Slide armor stop insert over conductor and sealing compound, then back against armor. Pack remaining sealing compound.

7.3.2 DIRECT CABLE ENTRY

When the selected cable has spaces through which ignited gas can travel, it is necessary to install the cable with a barrier type cable gland. (See Fig. 7.3.2) The barrier glands are supplied with a 2 part epoxy compound to prevent the migration of gases and pressure piling of ignited hot gases. The only exception to this rule is if the enclosure contains only terminals or other nonsparking devices, or if the volume of the enclosure is less than 2 liters. In these instances a standard Ex-d type cable gland may be used. Figure 7.32 Installing a TMCX Terminator

1. Prepare cable.

2. Install body into enclosure. Slide gland nut and intermediate body onto cable.

3. Mix sealing compound and pack conductors over armor.

7.3.4 MINERAL INSULATED METAL SHEATH CABLES (MIMS)

When MIMS cable is selected (with or without an outer protective sheath), the cable gland assembly and sealing pot must be Ex-d certified and installed strictly in accordance with the manufacturers instruction and certificate conditions of use. This type of cable is often used for fire and gas protection systems due to its high resistance to temperature and integrity during a fire.

5. Insert cable assembly into body.

6. Thread intermediate body with gland nut onto body. Tighten intermediate body, then gland nut.

Cooper Crouse-Hinds Ex Digest Flameproof Enclosures

Most Ex-protected equipment are certified to temperatures of -20C. For those regions with more extreme temperatures (-45C), self regulating heaters can be installed in the enclosures to raise the temperature to the required -20C.

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Conduits terminated in flameproof enclosures must have suitable and compatible threads. If the threads are the parallel (metric) type at least 8 axial threads must be engaged. For tapered (NPT) threads at least 5 full threads must be engaged for groups C and D and 7 full threads for Group B.

7.4 WEATHER-PROOFING OF FLAMEPROOF JOINTS

When flameproof enclosures are installed in areas where there is the possibility of water or other liquid ingress, it is necessary to specify gasketed enclosures using O-rings which are not a part of the flameproof function. Under no circumstances should users substitute unauthorized O-ring gaskets or seals. If a replacement gasket is required, it must be in accordance with the original manufacturers specification.

7.6 CONDUIT SEALS

Conduit seals, sometimes referred to as Seal-offs or Stopping Devices, are often required between the conduit and the enclosure to prevent migration of gas, vapor or liquids from or to the installed enclosure. These may also be necessary when a conduit passes from a safe area to a hazardous area.

Use only manufacturers specified O-rings as on the Cooper Crouse-Hinds Ex-d threaded junction box

Conduit seals are available from Cooper Crouse-Hinds for the North American market or from Nortem in Spain for ATEX approved seals.

7.4.1 COLD TEMPERATURE APPLICATIONS

Most Ex-protected equipment are certified to temperatures of -20C. For those regions with more extreme temperatures (-45C), self regulating heaters can be installed in the enclosures to raise the temperature to the required -20C. See Chapter 14 for a complete discussion of cold temperatures.

The main purposes of sealing fittings are: Restrict the passage of gases, vapors or flames from one portion of the electrical installation to another at atmospheric pressure and normal ambient temperatures Limit explosions to the sealed-off enclosure Prevent pre-compression or pressure piling in conduit systems. Sealed fittings are recommended for installation: At each entrance to an enclosure housing an arcing or sparking device when used in Class I, Division 1 and 2 and Zone 1 and 2 classified hazardous areas. To be located as close as practical and, in no case, more than 18" from such enclosures. At each entrance of 2" size or larger entering the enclosure or fitting housing terminals, splices or taps. To be located as close as practical and, in no case, more than 18" from such enclosures. In conduit systems when leaving the Class I Division 1 or Division 2 classified Hazardous Locations. In cable systems when the cables are capable of transmitting gases or vapors through the cable core and when these cables leave the Class I, Division 1 or Division 2 classified Hazardous Locations.

7.5 CONDUIT ENTRY

Conduit entry into flameproof enclosures is not a common installation specification in Europe. It is a common installation practice in North America and other countries influenced by the U.S. National Electric Code. The selected conduit must be either solid drawn or seam welded. When it is necessary to use flexible conduit, e.g. to motor terminal boxes or other apparatus which may vibrate during normal operation, the flexible conduit must have an outer protective sheath, mechanical strength and resistance to corrosion.

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Cooper Crouse-Hinds Ex Digest Flameproof Enclosures 7.6.2 TRADITIONAL METHOD OF SEALING

Cooper Crouse-Hinds offered sealing fittings for use in hazardous areas for over 80 years. Chico A sealing compound used in conjunction with Chico X packing fiber has been the traditional method used to seal the sealing fittings for this entire time period. The traditional method involves carefully packing a fiber dam using the Chico X fiber in the bottom of the conduit hub in vertical installations and in both conduit hubs in horizontal installations. The packing of the fiber dam is critical to the pouring of a reliable seal. The fiber dam keeps the sealing compound in the chamber of the sealing fitting while it cures and hardens. The fiber dam is also used to separate the individual conductors so that the sealing compound seals around each conductor. If the electrical conductors are not properly separated, gases can migrate through the seal, making the seal ineffective. Separation of the conductors is very tedious and time consuming. It is a skill that is learned over time and should be done by a skilled and trained craftsman. Modern day applications involving multi-conductor cabling and control wiring can create a situation where you have 10 to 20 wires in a single sealing fitting. After a fiber dam is formed, the sealing compound is ready to be mixed. The Chico A sealing compound is typically supplied in a plastic container. The user must measure and mix the proper ratio (2:1) of Chico A compound with clean water and be ready with cleaning vessels, mixing utensils and a funnel to pour the compound into the sealing fitting.

7.6.1 NEW ADVANCEMENTS IN EXPLOSIONPROOF SEALING FITTINGS

Cooper Crouse-Hinds new Chico SpeedSeal Compound offers a brand new method of explosionproof sealing which takes 80% of the labor out of pouring a seal, allowing one to reliably install a complete seal in less than five minutes. This revolutionary compound comes in a self-contained applicator kit that eliminates the need for measuring before mixing. Simply pump the cartridge to mix the material, inject the pre-measured amount in to the sealing fitting, and youre done. Pump, Inject, Sealed. After injection, the Chico SpeedSeal compound expands to four times its original size, physically separating the conductors as it expands, and completely filling the fitting. The difficult and timeconsuming task of separating the individual conductors with Chico X fiber has been eliminated. The compound begins to set in 4 to 10 minutes and hardens in 20 minutes, resulting in a dense, strong mass which is unaffected by water, petroleum products or temperature changes. Chico SpeedSeal compound may be used to seal in both horizontal and vertical installations. It may be used with type EYS and EYD sealing fittings in " to 2" trade sizes, in Class I, Division 1 and 2, Groups C & D and Class II, Division 1 and 2, Groups E, F, & G hazardous areas.

PUMP

INJECT

SEALED

Cooper Crouse-Hinds offers the labor savings Chico A Intrapak. A twocompartment premeasured amount of Chico A sealing compound and water, the Chico Intrapak eliminates the step of measuring before mixing. Simply squeeze to break the water compartment, mix together, and attach the nozzle to pour directly into the sealing fitting.

Cooper Crouse-Hinds Ex Digest Flameproof Enclosures 7.6.3 NEW METHOD OF SEALING

The traditional method of sealing is very effective. However, there are some difficulties associated with this traditional method that the new Chico SpeedSeal Compound addresses. Labor intensive and expensive - In a national survey of North American installers, the average time to properly prepare and pour a seal with the traditional method ranged from 48 minutes for a seal to over an hour and a half for a 2 sealing fitting. Solution - Chico SpeedSeal Compound removes over 80% of the labor required to properly prepare and pour a seal. A reliable seal in guaranteed in five minutes, every time.
Traditional 100 90 80 Time (In Minutes) 70 60 50 40 30 20 10 0 1/2" 1" Sealing Fitting Size 2" Chico SpeedSeal

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Cooper Crouse-Hinds new Chico SpeedSeal Compound offers a brand new method of explosionproof sealing which takes 80% of the labor out of pouring a seal, allowing one to reliably install a complete seal in less than five minutes.

=$91

=$56 =$44

=$5

=$5

=$5

Why spend 50 minutes preparing and pouring a seal whem you can do it easier in five?

Separation of conductors - The traditional method of sealing requires that fiber be used to form a dam between the integral bushing of the sealing fitting and the end of the conduit. When packing a fiber dam each electrical conductor must be individually separated to ensure that the sealing compound surrounds each conductor. With the increased use of multi-conductor cabling, this is a difficult and time consuming process, and must be done at each end of the sealing fitting in a horizontal sealing fitting. Solution - Chico SpeedSeal Compound expands to four times its original size in the sealing fitting, eliminating the need to separate the individual conductors with Chico X fiber. The conductors are separated automatically as the sealing compound expands. Horizontal installations do not require fiber dams. Long cure times - Traditional sealing compounds take from 8 hours to 72 hours to cure. During this cure time, the seal and the conductors must be left undisturbed. Any movement may jeopardize the integrity of the seal. This creates problems for OEM customers who are using the sealing fitting in a manufactured product. The OEM must move their product from production until the seal is cured. Solution - The Chico SpeedSeal Compound sets up in 4 to 10 minutes and is completely hardened in 20 minutes. OEMs can now pour a seal and be back in production in less than 20 minutes.

7.7 FACTORY SEALED DEVICES

Factory sealed devices eliminate the time-consuming handwork of field poured seals. The seal is designed into the device and is ready for installation as it comes from the box. Factory sealed devices include control stations, pilot lights, panelboards, lighting fixtures, plugs and receptacles, bell and horn signals and clocks. The most common method of factory sealing utilizes a flameproof (explosionproof) contact block. Terminal connections and contacts are permanently molded and sealed into the device.

Small explosionproof components eliminate the need for seals on control stations, breakers and switches

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Cooper Crouse-Hinds Ex Digest Flameproof Enclosures 7.9 CHECKLIST FOR THE INSTALLATION OF FLAMEPROOF ENCLOSURES
The final selection and installation check of flameproof enclosures should include the following technical criteria: Is the apparatus suitable for the Area Classification? Is the Gas Group for the installation correct? Is the T Classification appropriate and below the auto ignition temperature of the gas likely to be present in the surrounding atmosphere? Are all the apparatus bolts, cable entry devices and blanking plugs correctly installed and tightened? Are the cable entry devices and blanking plugs certified Ex-d? Are the flange, spigot, or threaded flamepaths cleaned and greased? Grease should be that as specified by the manufacturer such as Crouse-Hinds STL, or HTL for high temperatures. Is the enclosure cover correctly installed with all the manufacturers bolts? Are they tightened down? Is the earth/ground connection tight and connected to the main earth/ground system with the correct size of bonding conductor? Are there are no solid obstructions adjacent to the flamepath? Has a check been carried out to ensure that there are no unauthorized modifications to the apparatus? For complete information on sealing requirements refer to the Cooper Crouse-Hinds Code Digest and Canadian Code Digest. For questions or comments, please contact the author at paul.babiarz@crouse-hinds.com

7.8 GROUND CONTINUITY

When the threads of conduits are exposed to the environment, some protective measures must be taken to prevent possible mechanical damage or corrosion. Electrical continuity must also be maintained across threaded joints. If there is any doubt then an external ground bond wire should be installed.

Cable tray must be bonded for earth continuity.

The XJG provides an internal grounding continuity and expansion capability. It can be supplied with the optional bonding jumper shown for visible ground induction.

The XD coupling provides flexible movement in all directions and internal ground continuity.