In many industries, such as the chemical, oil and gas industries, but also in numerous workshops, explosion-protected lamps are of great importance for safety and efficiency. In this article, you will learn everything you need to know about the different designs, the requirements for explosion-protected lamps and their typical areas of application. We also present specific solutions from our partner ZALUX.
Explosion-proof lamp: Definition
What are explosion-proof lamps? According to the definition, explosion-proof lamps are specially developed lighting equipment that is used in potentially explosive atmospheres. It meets strict safety standards to prevent the ignition of explosive gases, vapors or dusts caused by sparks or surface temperatures. Explosion-proof lamps are used in industries such as chemicals, petrochemicals and mining. In principle, wherever reliable safety and standard-compliant certifications have top priority.
Ex-protected luminaires and the designs
Ex-protected lights come in various designs that are suitable for different applications. We have summarized the most common designs and applications for you below:
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Ceiling lights are ideal for large halls and workshops and ensure uniform illumination.
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High-bay luminaires have been specially developed for warehouses and shelving systems and provide precise light in high areas.
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Street lights increase visibility in potentially explosive outdoor areas and improve safety here.
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Work lights are characterized by their mobility and are used in hazardous areas with flexible requirements.
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Mobile lights are convincing due to their versatility and are used in changing locations or in emergencies.
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Escape route luminaires reliably mark escape routes and remain functional even in critical situations thanks to the emergency power supply.
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Warning lights provide a clear signal in the event of danger or critical operating conditions.
What are the requirements for explosion-proof lamps?
The main explosion protection requirements for explosion-protected lamps include, in particular, classification according to hazard zones, the choice of ignition protection types, surface temperature control and compliance with relevant certifications.
Luminaires are classified according to the hazard zones that define the risk of explosion.
- Zone 0 designates areas in which explosive atmospheres are constantly present, while Zone 1 and Zone 2 represent a sporadic or rare risk.
- Each zone requires specific protective measures, which are ensured by selecting the appropriate ignition protection types such as "e" (increased safety), "d" (explosion-proof enclosures) or "i" (safe enclosed systems).
| Zone | Description | Example of locations | Risk |
| Zone 0 | Area in which an explosive atmosphere is present permanently or for long periods of time. | Inside tanks, containers or pipelines containing flammable gases. | Constantly or frequently present |
| Zone 1 | Area in which an explosive atmosphere may occasionally occur during normal operation. | In the vicinity of tank openings, vents or process systems. | Occasionally available |
| Zone 2 | Area in which an explosive atmosphere does not normally occur and, if it does, only for a short time. | Environments of leaks or safety valves. | Rarely and only for a short time |
Another critical factor is the surface temperature of the lamps. It must not lead to the ignition of flammable gases, vapors or dusts and must therefore be carefully controlled.
Finally, certifications such as ATEX or IECEx provide the necessary safety and confirm compliance with international standards.
b) Luminaire-specific requirements
Ex-protected luminaires must not only comply with strict regulations, but also meet specific requirements in order to function effectively in hazardous environments.
Brightness
The brightness of explosion-protected luminaires in the application is a key criterion which, in addition to safety, also influences the lighting conditions in a work area and therefore also directly affects work efficiency. The terms lumen (lm) and lux (lx) should be mentioned here:
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Lumen (lm): Lumen is the unit that describes the total amount of visible light emitted by a light source. A higher lumen figure indicates a brighter light source. For example, a standard 60-watt light bulb emits around 800 lumens.
- Lux (lx): Lux, on the other hand, is the unit that indicates how much light falls on a certain surface. One lux corresponds to one lumen per square meter. In an office, an illuminance of around 500 lux is recommended, while industrial applications often aim for 300 to 1000 lux, depending on the specific requirements.
Color temperature
The color temperature influences how people perceive colors in their surroundings and their concentration and well-being. It is measured in Kelvin (K):
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Warm white (2700K-3000K): For relaxed, less intense lighting conditions, ideal for lounges.
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Neutral white (4000K): Well suited for general work areas.
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Daylight white (5000K-6500K): Perfect for environments where high concentration and accuracy are required, such as in laboratories or when assembling precise devices.
Construction and materials
Explosion-proof lamps should always be made of robust, corrosion-resistant materials such as aluminum, stainless steel or special plastics. In areas where explosion-protected luminaires are used, the materials must be able to withstand mechanical stresses as well as aggressive chemicals and high temperatures.
In addition, a well thought-out construction and intelligent design are important for explosion-protected luminaires in order to prevent the ingress of dust and moisture. According to DIN EN 60529, the international standard for protection against the ingress of water and solid foreign bodies, many explosion-protected luminaires must guarantee at least an IP65 degree of protection, which means that they are dust-tight and protected against water jets.
Energy efficiency
Modern explosion-protected lamps in use have a high energy efficiency rating (at least A), help to reduce operating costs and lower the environmental impact. LED technology is a modern solution here, creating both bright lighting conditions and low energy consumption.
A typical LED-Ex lamp can provide a light output of 100 lm/W. An LED light with an output of 50 watts therefore produces around 5000 lumens. Compared to conventional HMI or halogen lamps, this means considerable energy savings, as these often only have 60 and 80 lm/W.
Installation & maintenance
Maintenance-friendly designs of explosion-protected lamps, easy access for lamp replacement and electrical connections are essential for the intended use of explosion-protected luminaires. A good example of this is modular designs, where the explosion-proof luminaire can be dismantled into units. This gives the technician the option of carrying out maintenance and repair work with minimal effort.
Special functions
Additional functions such as emergency power supply, afterglow function and the integration of DALI protocols (Digital Addressable Lighting Interface) for intelligent lighting control significantly increase safety and optimize the operation of the explosion-proof lamps in critical applications.
Example of special functions:
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Emergency power supply: In a petrochemical plant, it is of the utmost importance that emergency lighting is automatically activated in the event of a power failure to ensure a safe evacuation.
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DALI protocol: Multifaceted control options enable flexible adjustment of lighting conditions depending on work tasks or times of day.
Applications and solutions for explosion-protected luminaires from ZALUX
While our development and production focus at SEIKOM Electronic is on industrial measurement and control technology, we work closely with our partner ZALUX from Spain on explosion-protected luminaires. ZALUX is part of the German Trilux Group, has more than 40 years of experience and produces more than 3.5 million luminaires per year with almost 400 employees. The following simplified overview shows the available model ranges in the field of explosion-proof luminaires.
We would like to focus on 2 series below: the Acquex ceiling and wall light and the OREX high-bay light.
Acquex
The Acquex series brings a range of waterproof and robust explosion-proof luminaires that are specially designed for high humidity environments. The explosion-proof lamps in use are not only energy-efficient, but also equipped with various special functions that significantly increase user-friendliness. They are ideal for use in petrochemical plants and other humid environments.
Orex
The Orex series, on the other hand, is known for its versatility. The explosion-proof luminaires are ideal for demanding environments where both luminous intensity and safety play a role. They score with high energy efficiency and are available in different versions to meet the specific requirements of each industry.
Summary and conclusion on explosion-protected luminaires and their significance
Ex-protected lights are of great importance in many industrial applications where safety requirements have the highest priority. At SEIKOM Electronic, we have a wide range of explosion-proof lamps that meet all relevant standards and are characterized by quality and durability.
For further information or questions about our products, please contact us personally and competently.
