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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

EXPLOSIONPROOF

FLAMEPROOF

Field Drilling

Acceptable

Must be drilled by manufacturer

Pressure testing

4 times maximum

1.5 times maximum

Construction

Heavier

Lighter

Joints
Heat rise

Threaded, flat, labyrinth (serrated)

Not a consideration

Threaded, flat, spigot

Factor which limits components inside

Wiring room
Entries

Major design consideration

Field or factory drilled directly into enclosure

Not a major design consideration

Factory drilled directly into
enclosure or field drilled into an
Ex-e enclosure (indirect entry)

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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.

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

Distance

IIA

10 mm

IIB

30 mm

IIC

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.

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

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).

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Flameproof Enclosures

7.2.1 FLAMEPATHS & JOINTS IIB VS IIC

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).

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

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.

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.

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.

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

II A

IIB

IIC

Min. Joint
Width (mm)

100 cm3

Maximum Gap for Enclosures with Volume

> 100 cm3
> 500 cm3
> 2000 cm 3
3
3
500 cm
2000 cm

0.3

9.5

0.35

0.35

12.5

0.4

0.4

0.4

0.4

25

0.5

0.5

0.5

0.5

0.3

9.5

0.3

0.3

12.5

0.3

0.3

0.3

0.2

25

0.4

0.4

0.4

0.4

0.2

9.5

0.2

0.2

12.5

0.2

0.2

0.2

0.15

25

0.2

0.2

0.2

0.2

0.1

9.5

0.1

0.1

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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.

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

Crouse-Hinds supplies Universal

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

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

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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Flameproof Enclosures

7.3.2 DIRECT CABLE ENTRY

7.3.3 CABLE GLANDS

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

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.

1. Prepare cable.

2. Install body into enclosure. Slide

gland nut and intermediate body
onto cable.

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

3. Mix sealing compound and pack

conductors over armor.

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.

5. Insert cable assembly into body.

6. Thread intermediate body with

gland nut onto body. Tighten
intermediate body, then gland nut.

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.

Cooper Crouse-Hinds Ex Digest

Flameproof Enclosures

45

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.

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

7.6 CONDUIT SEALS

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.

Use only manufacturers specified O-rings as on the Cooper Crouse-Hinds

Ex-d threaded junction box

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.

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.

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.

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

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.

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Flameproof Enclosures

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

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.

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.

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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.

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.

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

Chico SpeedSeal

100

=$91

90
Time (In Minutes)

80
70
60

=$56

50
40

=$44

30
20
10

=$5

=$5

=$5

0
1/2"

1"

2"

Sealing Fitting Size

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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Flameproof Enclosures

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.

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

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.