Unit 4:

Increased Safety
EEx e / Ex e
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Objectives:

On completion of this unit, ‘Increased Safety EEx e / Ex e Apparatus’, you

should know:

a. The principle of operation.

b. The principle design features.

c. The methods for estimating terminal content of enclosures.

d. The installation requirements according to BS EN 60079-14.

e. The inspection requirements according to BS EN 60079-17.

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Increased Safety EEx e / Ex e
The explosion protection concept Increased Safety was invented in Germany where it has
been widely used for many years. It is has gained in popularity because it has a number of
advantages for certain applications over the traditional flameproof method of explosion
protection. America has traditionally relied on explosion-proof enclosures (similar to
flameproof) in hazardous locations, and the prospect of using an Increased Safety
enclosure, which is not designed to withstand an internal explosion, as an alternative, has
probably been viewed with a little trepidation.
This method of protection has a good safety record and comparable with the other methods
of protection. The letter ‘e’ which symbolises this method of protection is taken from the
German phrase ‘Erhohte Sicherheit’, which roughly translated means ‘increased security’.
Typical applications are induction motors, lighting fittings and junction boxes.

Standards

Electrical apparatus for explosive gas atmospheres.

BS EN60079-7: 2007
Increased Safety ‘e’
BS EN50 019: 2000 Increased Safety enclosure ‘e’
BS 5501: Part 6: 1977 Increased Safety enclosure ‘e’
BS 4683: Part 4: 1973 Type of protection ‘e’
Construction and Test of Electrical Apparatus, Type of
IEC 60079-7: 2001-11
Protection “e”
Electrical apparatus for explosive gas atmospheres: Part 14
BS EN60079-14: 2008 Electrical installations in hazardous areas (other than
mines)
Electrical apparatus for explosive gas atmospheres: Part 17
BS EN60079-17: 2007 Inspection and maintenance of electrical installations in
hazardous areas (other than mines)
BS 5345: Part 6: 1978 Code of Practice for the Selection, Installation and
(Withdrawn) Maintenance of Increased Safety apparatus.

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Definition
‘A type of protection applied to electrical apparatus in which additional measures are applied
so as to give increased security against the possibility of excessive temperatures and of the
occurrence of arcs and sparks in normal service or under specified abnormal conditions’.

EPL: Gb (ATEX Cat 2G)

Zones of use: 1 & 2 (Based on traditional selection approach)

Ambient Temperatures
Increased Safety enclosures are normally designed for use in ambient temperatures in the
range -20 °C to +40 °C unless otherwise marked.

Principle
The safe operation of Increased Safety apparatus is dependent on the prevention of any
source of ignition, i.e. excessive surface temperatures, arcs or sparks, which might
otherwise be produced by internal or external parts of the apparatus. Special design features
are, therefore, incorporated in the apparatus by the manufacturer and are as follows.

Component
certified
enclosure

Gasket Component
certified
terminals
Note:
Gaskets are also
fitted between Earth stud
gland plates and
the enclosure

Gland plates

1. Mechanically strong enclosure resistant to impact - tested to 4 or 7 joules impact

energy depending on application.
2. Ingress protection against solid objects and water - minimum IP 54.
3. Terminals manufactured from high quality insulation material.
4. Specified creepage and clearances incorporated in the design of terminals.
5. Terminal locking devices to ensure conductors remain secure in service.
6. Certified de-rating of terminals.
7. Terminal population of enclosure limited by circuit design.
8. Close excess current circuit protection.

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Plastic enclosures
Plastic enclosures as illustrated below (with part of cover removed to show interior) are
constructed from an anti-static GRP material that has an insulation resistance less than
1G and are highly resistant to corrosion. These enclosures are designed to resist an
impact of up to 20 Nm and may or may not be fitted with an internal continuity plate.

Internal continuity
plate

Sample certification label

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Increased Safety Terminals
The terminals installed in an Increased Safety enclosure must be ‘component certified’
terminals. They will be manufactured from good quality materials such as Melamine,
Polyamide and, for special applications, Ceramic. These materials, which have good thermal
stability, have been subjected to a ‘Comparative Tracking Index (CTI)’ test to determine their
resistance to tracking. Ex e terminals will be designed to have adequate
‘creepage/clearance’ distances to avoid the possibility of ‘tracking’ between terminals and
between terminals and earth. The following definitions are relevant:

Clearance distance:
Creepage distance:
Tracking:
The shortest distance in air between two conductive parts.
The shortest distance between two conductors along the
surface of an electrical insulating material.
The leakage current which passes across the
contaminated surface of an insulator between live
terminals, or live terminals and earth.

Creepage and Clearance Distances

Clearance and creepage paths

to extend to adjacent clamping
screw

Clearance
29.75mm
Creepage
path
30.6mm

Terminals
Partition
Screw heads
Clearance & creepage
path 26.4mm

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Creepage Distances Relative to Voltage and Grade of Insulation
The following table from BS EN60079-7 shows the creepage distances relative to the grade
of material and applied voltage.

Voltage (see note 1) Minimum creepage distance Minimum clearance

U r.m.s a.c. or d.c. (mm) (mm)
(V)
Material group
I II IIIa
10 ( see note 3 ) 1.6 1.6 1.6 1.6
12.5 1.6 1.6 1.6 1.6
16 1.6 1.6 1.6 1.6
20 1.6 1.6 1.6 1.6
25 1.7 1.7 1.7 1.7
32 1.8 1.8 1.8 1.8
40 1.9 2.4 3.0 1.9
50 2.1 2.6 3.4 2.1
63 2.1 2.6 3.4 2.1
80 2.2 2.8 3.6 2.2
100 2.4 3.0 3.8 2.4
125 2.5 3.2 4.0 2.5
160 3.2 4.0 5.0 3.2
200 4.0 5.0 6.3 4.0
250 5.0 6.3 8.0 5.0
320 6.3 8.0 10.0 6.0
400 8.0 10.0 12.5 6.0
500 10.0 12.5 16.0 8.0
630 12.0 16.0 20.0 10.0
800 16.0 20.0 25.0 12.0
1000 20.0 25.0 32.0 14.0
1250 22.0 26.0 32.0 18.0
1600 23.0 27.0 32.0 20.0
2000 25.0 28.0 32.0 23.0
2500 32.0 36.0 40.0 29.0
3200 40.0 45.0 50.0 36.0
4000 50.0 56.0 63.0 44.0
5000 63.0 71.0 80.0 50.0
6300 80.0 90.0 100.0 60
8000 100.0 110.0 125.0 80.0
10000 125.0 140.0 160.0 100.0
Note 1: Voltages shown are derived from IEC 60664-1. The working voltage may exceed
the voltages given in the table by 10%. This is based on the rationalisation of
supply voltages given in table 3b of IEC 60664-1
Note 2: The creepage distance and clearance values shown are based on a maximum
supply voltage tolerance of +10%.
Note 3: At 10 V and below, the value of CTI is not relevant and materials not meeting the
requirement for material group IIIa may be acceptable.

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Increased Safety Terminals (continued)
Since the terminals for Ex e enclosures have been designed to a high specification, i.e.
made from high quality materials with specified creepage and clearance distances, it is
important that sound installation practice is carried out so as to avoid compromising these
design features.

SAK-series modular terminals

SAK2.5 / EK4 terminal rail SAK2.5 terminal SAK2.5 certification

W-series modular terminals

WDU4 terminal WPE4 earth terminal

Terminal Locking mechanism

It is essential that conductors are securely connected in the terminals to prevent sparks
occurring as a result of loose connections. The illustration below shows how this is achieved.

Threaded leaves

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Increased Safety Terminals (continued)
The table below shows for the various sizes of SAK terminals, the maximum conductor size,
the maximum current for non-hazardous area use and the maximum current for Ex e
equipment use. It will be noted that for most of the terminals there is nearly a 50% de-rating
for Ex e purposes compared to that for non-hazardous area use. This de-rating, along with
other considerations, ensures that internal and external surface temperatures are kept within
prescribed limits.

Increased Safety Industrial Maximum

Terminal Conductor
Maximum Current Current
Type Size
(amps) (amps)
SAK 2.5 2.5 15 27
SAK 4 4 21 36
SAK 6 6 26 47
SAK 10 10 37 65
SAK 16 16 47 87
SAK 35 35 75 145
SAK 70 70 114 220

Note: Generally, only one conductor per terminal side is permitted unless otherwise
permitted by the equipment certificate.

Linking terminals

1. Mounting rail;
2. Terminals – certified
components;
3. End plate;
4. End bracket;
5. Distance sleeve;
6. Partition;
7. Copper cross-connection;
8. Zinc plated screw;
9. Copper cross-connection;
10. Copper cross-connection.

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Cable gland selection & installation
Cable glands used on Ex e enclosures are required to maintain the IP rating of the
equipment and withstand a 7J impact. Uncertified cable glands (not plastic) manufactured
to BS6121 achieve this requirement and prior to Dec-2007 were deemed suitable. The
latest standards, however, has effectively removed this option by virtue of the requirement
for revised ‘seal aging’ tests involving repeated heating and cooling cycles, which is now a
requirement for all cable glands as detailed in IEC 60079-0. The latest issue of IEC
60079-14: 2007-12 now requires all cable glands to be certified or approved by the
manufacturer and comply with IEC 60079-0. Cable glands may be Ex e, Ex d, or dual
certified Ex de. The illustrations below show the minimum requirements for the installation
of cable glands and accessories, i.e. earth tags, IP washers, serrated washers and locknuts,
depending on whether the enclosure is metal, or plastic with or without an internal continuity
plate, and the entries are threaded, or unthreaded.

Note: Minimum requirements infer maintaining IP54 which a threaded entry 6mm in
length will achieve.

Metal enclosure
without removable
gland plate and Metal enclosure
has unthreaded with threaded
entries entries 6mm
long

Enclosure wall
or gland plate

Metal enclosure
with removable
gland plate and
Plastic enclosure clearance entries
with clearance
entries and no
internal continuity
plate

Enclosure wall
or gland plate

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Closing unused cable entries
Unused cable entries can be closed using plastic Ex e stoppers, illustrated below, to maintain the IP
rating of enclosures

Ex e enclosure installation requirements (typical)

Increased Safety enclosures marked with a suffix ‘X’ require the installer to refer to the
‘special conditions for safe use‘ that are listed in the enclosure certificate. Listed below
are some, but not all, of the conditions that may be specified in a given certificate.

1. Enclosure content should not be modified without consulting the

manufacturer.
2. All terminal screws, used and unused, should be tightened down.
3. Conductor insulation should extend to within 1 mm from the metal throat of the
terminal.
4. Partitions should be fitted at either side of terminal linking assemblies. (See diagram
on page 11)
5. Only one conductor should be fitted to each terminal side (unless more than one is
permitted in the equipment certificate).
6. An additional single conductor, min 1.0 mm2, may be connected within the same
terminal way when an insulated comb is used.
7. Only the conductors from each cable entry shall be loomed together. (See diagram
below)
8. All unused cable entries should be closed using stopping plugs as specified in the
enclosure certificate. (See diagrams above)
9. All lid and gland plate bolts must be fully tightened after installation.

Cores from 4-cable

glands are loomed

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Estimation of Terminal Population
The number of terminals which can be installed in a given size of enclosure is limited and
several methods have been developed by manufacturers for this purpose. These are:

Enclosure Factor: A method used in apparatus manufactured to BS 4683 Part 4

in which the terminal content is assessed by dividing the
‘enclosure factor’ by the certified current rating of a given
terminal.

Load Limit: Similar to ‘enclosure factor’ but used only on apparatus

manufactured to BS 5501 Part 6.

Kelvin Rating: Normally used for high current applications and apparatus
manufactured to BS 4683 Part 4 and BS 5501 Part 6. In this
method, enclosures and terminals are assigned a temperature
rating. Enclosures will normally be limited to a temperature rise
of 40K for a T6 temperature rating, but the temperature for the
terminals will be dependent on their type, rated current, size of
associated conductor, and the size of enclosure in which they
are installed. This involves the use of tables which are
provided by the manufacturer. Once the terminal ‘K’ rating has
been established, it is divided into the ‘K’ rating for the
enclosure to give the number of terminals of one type which
may be installed.

Max Dissipated Power: This is the latest method for estimating the terminal content of
enclosures and has been used for equipment manufactured to
BS 5501 Part 6, BS EN50019 and BS EN60079-7. In this
method, enclosures are assigned a ‘watts dissipation’ rating,
but the rating of the terminals is determined by use of a unique
table (provided by the manufacturer) for the enclosure. This
table provides the ‘watts dissipation’ of the terminal through
consideration of conductor size and load current. The terminal
content is determined by dividing the ‘watts dissipation’ value
for the terminal into that for the enclosure.

Another method used by manufacturers is to specify the maximum current per pole and
also the maximum current per mm2.

Examples of labels with the above information are shown overleaf.

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Examples of labels

(a) Enclosure factor (b) Load limit

Klippon Klippon
ENCLOSURE TYPE TB11 TYPE TB11EX S/No. 9364
BS 4683 Pt.4 Ex e II T6 EEx e II T6
BASEEFA No. Ex 77152/B BASEEFA CERT. No. EX84B1333X
MAX. CIRCUIT VOLTAGE 726 BS5501 Pt.6 (EN50 019)
ENCLOSURE FACTOR 416 LOAD LIMIT 600A
SERIAL NUMBER 1334

(c) Load limit (d) Maximum dissipated power

Klippon Klippon
TYPE TB12 S/No.867594 TYPE STB2 EEx II T6 S/No. T499
EEx e II T6 BASEEFA CERT. No. 86B 2138X
BASEEFA CERT. No. Ex84B3290X BS5501 Pt.6 (EN50 019)
BS5501 Pt.6 (EN50 019) MAX. DISSIPATED POWER 7 WATTS
LOAD LIMIT 40K

(e) Maximum current per pole and per sq. mm

HAWKE CABLE GLANDS Ltd.

BS5501: Pt.6: 1977

(EN50 019) EEx e II T6

BASEEFA No. Ex 8142BX

TYPE REF PL639 SERIAL No. 9960/89
PHASE-TO-PHASE 726
MAX VOLTS
PHASE-TO-EARTH
MAX.CURRENT DENSITY
AMPS PER SQ. MM 4
MAX AMPS PER POLE 10

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Sample Calculation using ‘Load limit’
The ‘Load Limit’ will be specified on the certification label of an Increased Safety enclosure,
as illustrated below, and represents the sum of all the circuit currents the enclosure is able to
carry without exceeding the temperature classification.
Thus, the number of terminals of one type which can be installed in a given enclosure is
simply the ‘Load Limit’ divided by the Increased Safety current rating of the terminal type to
be used, as demonstrated in the following calculation.

Enclosure Load Limit = 600

SAK 2.5 Ex e terminal rating = 15 A

Load Limit
Number of SAK 2.5 terminals =
SAK 2.5 terminal rating

600
=
15

= 40 SAK 2.5 terminals

Where the circuit current is below the certified current rating of the terminals, it may be
possible to base the terminal population on the circuit current provided it will not exceed the
assigned value. Assuming a circuit current of 10 A, the calculation is as follows.

Enclosure Load Limit = 600

Circuit current = 10 A

Load Limit
Number of SAK 2.5 terminals =
Circuit current

600
=
10

= 60 SAK 2.5 terminals

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Increased Safety EEx e / Ex e Motors
These motors are similar in appearance to standard industrial motors and inspection of the
certification/rating plate is usually necessary to identify them. These motors are not designed
to withstand an internal explosion and hence have special design features to prevent arcs,
sparks and excessive surface temperatures occurring both internally and externally. The
principal design features are:

1. Special attention to airgap concentricity and clearance of all rotating parts.

2. Impact testing of motor frame.
3. Temperature rise 10 °C lower than normal.
4. T2 or T3 surface temperature limitation.
5. Compliance with tE time.
6. Special terminal block with specific creepage/clearance distances and locking
devices on terminals.
7. Minimum ingress protection to IP54.

Under stall (locked rotor) conditions, the rotor surface temperature will normally increase
faster than that of the stator windings, and hence, the T-rating applies to both internal and
external surface temperatures.
Under fault conditions, the motor must trip within the tE time specified on the motor data
plate.

tE time = 10 seconds

tE time

Defined as: ‘the time taken to reach the limiting temperature from the temperature
reached in normal service (i.e. hot) when carrying the starting current IA at maximum
ambient temperature.
In the graph shown on page 18, ‘OA’ represents the maximum ambient temperature and
‘OB’ the temperature reached at maximum rated current. If the rotor locks as a result of a
fault, the temperature will rise rapidly towards ‘C’ as shown in part 2 of the graph, which is
less than the T rating of the motor. The time taken to reach ‘C’ from ‘B’ is known as the tE
time, and during fault conditions the thermal overload device in the motor starter must trip
the motor within this time.

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Increased safety motors are intended for continuous duty only, i.e. they are unsuitable for
applications which require frequent stopping and starting and/or long run-up times.

Determination of tE Time

Max limiting temperature

 C
Temperature 0C

A
0 Hours Secs
Time
Rotor locked

Limiting Temperature
Temperature limited either by selected T-rating, or limit for class of winding Insulation
material.

A = Maximum ambient temperature.

B = Maximum temperature at rated current.
C = Limiting temperature.
 = Temperature.
(1) = Temperature rise at rated current.
(2) = Temperature rise during locked rotor test.
tE = Time from maximum temperature (B) at rated current to limiting
temperature (C).

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Tripping Characteristic of Thermal Overload device
The thermal overload device will be selected for suitability according to its tripping
characteristic. The tE time and IA/IN current ratio are influential in the selection of the device
and are marked on the motor nameplate.

40

20
time

10
E
t

1
3 4 5 6 7 8 9 10
I A / I N current ratio

IN = rated current of motor.

IA = locked rotor current of motor.

Example 1: IA/IN = 5 and tE time = 10 secs

The above characteristic would trip the motor after 8 secs, which is
within the tE time and therefore acceptable.

Example 2: IA/IN = 4.5 and tE time = 8 secs

For these values the tripping time is 10 secs, which is outwith the tE
time assigned to the motor, therefore an overload device with this
characteristic would not be suitable for the values specified.

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Typical faults

The following list illustrates some examples of faults which will impair the integrity of
Increased Safety Ex e equipment.

1) Missing cover bolts;

2) Loose cover bolts;

3) Incorrect cover bolts;

4) Loose cable glands;

5) Incorrect cable glands;

6) Missing blanking elements (stoppers);

7) Incorrect blanking elements (stoppers);

8) Incorrect temperature class;

9) Incorrect ambient rating;

10) Damaged to enclosure;

11) Loose terminals;

12) Exposed conductor between core and terminal;

13) Missing partitions between linked and non-linked terminals;

14) Cores from more than one cable gland loomed.

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BS EN 60079-17 Table 1: Inspection Schedule for Ex’d’, Ex’e’, and Ex ‘n’
Installations (D = Detailed, C = Close, V = Visual)
Check that: Ex’d’ Ex’e’ Ex’n’
Grade of Inspection
D C V D C V D C V
A APPARATUS

1 Equipment is appropriate to the EPL / Zone classification * * * * * * * * *

2 Equipment group is correct * * * * * *
3 Equipment temperature class is correct * * * * * *
4 Equipment circuit identification is correct * * *
5 Equipment circuit identification is available * * * * * * * * *
6 Enclosure, glass parts and glass-to-metal sealing gaskets * * * * * * * * *
and/or compounds are satisfactory
7 There are no unauthorised modifications * * *
8 There are no visible unauthorised modifications * * * * * *
9 Bolts, cable entry devices (direct and indirect) and blanking
elements are of the correct type and are complete and tight
- Physical check * * * * * *
- Visual check * * *
10 Flange faces are clean and undamaged and gaskets, if any, *
are satisfactory
11 Flange gap dimensions are within maximal values permitted * *
12 Lamp rating, type and position are correct * * *
13 Electrical connections are tight * *
14 Condition of enclosure gaskets is satisfactory * *
15 Enclosed-break and hermetically sealed devices are undamaged *
16 Restricted breathing enclosure is satisfactory *
17 Motor fans have sufficient clearance to enclosure and/or covers * * *
18 Breathing and draining devices are satisfactory * * * * * *

B INSTALLATION

1 Type of cable is appropriate * * *

2 There is no obvious damage to cables * * * * * * * * *
3 Sealing of trunking, ducts, pipes and/or conduits is satisfactory * * * * * * * * *
4 Stopping boxes and cable boxes are correctly filled *
5 Integrity of conduit system and interface with mixed system is * * *
maintained
6 Earthing connections, including any supplementary earthing
bonding connections are satisfactory (e.g. connections are tight
and conductors are of sufficient cross section)
- Physical check * * *
- Visual check * * * * * *
7 Fault loop impedance (TN system) or earthing resistance * * *
(IT systems) is satisfactory
8 Insulation resistance is satisfactory * * *
9 Automatic electrical protective devices operate within permitted * * *
limits
10 Automatic electrical protective devices are set correctly (auto reset * * *
not possible)
11 Special conditions of use (if applicable) are complied with * * *
12 Cables not in use are correctly terminated * * *
13 Obstructions adjacent to flameproof flanged joints are in * * *
accordance with IEC 60079-14
14 Variable voltage/frequency installation in accordance with * * * * * *
documentation

C ENVIRONMENT

1 Equipment is adequately protected against corrosion, weather, * * * * * * * * *

vibration and other adverse factors
2 No undue accumulation of dust and dirt * * * * * * * * *
3 Electrical insulation is clean and dry * *

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Note 1: Apparatus using a combination of both ‘d’ and ‘e’ types of protection will require
reference to both columns during inspection.

Note 2: The use of electrical test equipment during execution of items B7 and B8) should
only be undertaken after appropriate steps are taken to ensure the surrounding
area is free of a flammable gas or vapour.

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