LED lighting for explosive atmospheres
Paint shops, filling stations, biogas plants, chemical plants and dusty production areas require ATEX-certified luminaires. Their job is to keep workers safe and rule out the lighting becoming a source of ignition.
We design, supply and install Ex luminaires precisely according to the zone classification of your plant – for gases, vapours and combustible dust, for zones 1/21 and 2/22, including emergency lighting of escape routes.
covered by three ranges of Ex luminaires – linear, industrial and floodlights
installations in paint shops, fuel loading facilities and biogas plants
energy savings in the Malieb production premises including the Ex paint shop
warranty on VULCAN, LENA Ex and FOX luminaires
Where explosive atmospheres occur
An explosive atmosphere forms wherever flammable gases, vapours or airborne dust mix with air in sufficient concentration. All it takes is a source of ignition – a spark or a hot surface – and an explosion occurs. An ordinary luminaire can be such a source. An Ex luminaire is built so that it cannot be, even in the event of a fault.
Paint shops and spray booths
Solvent and thinner vapours. The most common Ex application in our projects – Malieb, GIMMA, Konštrukta, Partizánske.
Fuels and gas
Filling stations, fuel loading, pump houses, gas storage tanks, rail and road tankers.
Biogas and chemicals
Biogas plants, chemical works, refineries, flammable substance stores – environments with gases and aggressive vapours.
Dusty operations
Woodworking, mills, silos, powder coating shops, bulk material handling – zones 21 and 22 for combustible dust.
Hazardous zones and luminaire categories
The zone is defined by the operator in the explosion protection document, based on how often and for how long an explosive atmosphere is present. Zones 0, 1 and 2 apply to gases and vapours (G), zones 20, 21 and 22 to combustible dust (D). The zone determines which luminaire category you may use.
A detailed explanation of the label markings is in our article How to read the markings on products for explosive atmospheres (in Slovak).
| ZONE | EXPLOSIVE ATMOSPHERE | CATEGORY | OUR LUMINAIRES |
|---|---|---|---|
| 0 / 20 | present continuously or for long periods | 1 | individually, after consultation |
| 1 / 21 | likely to occur occasionally in normal operation | 2 | VULCAN, FOX |
| 2 / 22 | not likely, only briefly and rarely | 3 | LENA Ex, VULCAN, FOX, emergency LENA Ex |
Three ranges of Ex luminaires
All are ATEX-certified for gas and dust, rated IP66 and come with a 5-year warranty. We choose them by zone, ambient temperature, mounting height and whether the job calls for a line above the workstation, area lighting or a pole-mounted floodlight.
Zones 1, 21 and 2, 22
VULCAN – explosion-proof industrial luminaire
Category 2, steel and stainless-steel body, toughened glass diffuser, IK10, operation from −40 °C to +55 °C, up to 16,800 lm, can be mounted in rows. For the chemical industry, refineries, paint shops and flammable substance stores.
Zones 2 and 22
LENA Ex – linear luminaire
Category 3, a replacement for T5/T8 fluorescent tubes in paint shops and spray booths, up to 9,425 lm, DALI dimming or an emergency module to order. The stand-alone LENA Ex emergency luminaire stays lit for 3 hours after a power failure.
Zones 1, 21 and 2, 22
FOX – floodlight for explosive atmospheres
Category 2, 20 to 200 W, up to 24,750 lm, optics from 30° to 120°, operation from −40 °C to +55 °C. For poles, walls and gantries – filling stations, fuel loading, biogas plants.
How we design lighting for an Ex zone
Ex luminaires cost more than ordinary industrial ones, so we specify them only where the zone classification actually requires them. At Malieb, 51 of the 266 new luminaires are Ex-rated – precisely in the paint shop areas. The rest of the hall is lit by standard high-efficiency luminaires.
- zone classification from the operator
- gas or dust – G or D
- temperature class by ignition temperature
- ambient temperature and mounting height
- DIALux calculation zone by zone
- emergency lighting of escape routes
With every delivery we enclose the ATEX certificates and luminaire data sheets for inspection and the explosion protection documentation.
Case study
Malieb production premises with an Ex paint shop
We provided the client with a complete lighting replacement service, including removal of the old luminaires and installation of the new ones. The original 400 W discharge lamps were replaced by 266 high-efficiency LED luminaires, 51 of them explosion-proof luminaires in the paint shop. We designed the layout, quantities and wattages in DIALux so that every area meets the required illuminance level and uniformity. The delivery also included anti-panic lighting and replacement of the switchboards.
Before
- 400 W industrial discharge luminaires
- high maintenance costs
- no emergency lighting
Solution
- high-efficiency LED luminaires
- 51 Ex luminaires in the paint shop
- anti-panic lighting
- switchboard replacement, 5-year warranty
energy savings
payback on the investment
LED luminaires, 51 of them Ex
floor area
How we work together
Site survey and zones
We look at the plant and take over the zone classification from your documentation.
DIALux calculation
The simulation determines the type, optics, number and layout of luminaires for each zone.
Quote with certificates
Price, savings, payback and the ATEX certificates of the specified luminaires.
Installation
During a shutdown, at the weekend or at night – to suit your operations.
Warranty and service
5-year warranty on Ex luminaires, documentation for inspection.
More installations in explosive atmospheres
All industrial lighting references →Frequently asked questions
Answers to what customers ask us most often about lighting for explosive atmospheres.
Who decides which zone a plant belongs to?
The operator, in the explosion protection document, usually together with a safety engineer or designer. We do not produce the zone classification – we specify luminaires whose category matches it and supply the certificates.
What is the difference between zone 1 and zone 2?
In zone 1 an explosive atmosphere is likely to occur occasionally even in normal operation; in zone 2 only rarely and briefly, for example during a fault. Zone 1 (and 21 for dust) requires category 2 luminaires – VULCAN and FOX. Zone 2 (22) needs only category 3, which includes LENA Ex. A luminaire of a higher category can be used in a less severe zone, but not the other way round.
Does the whole paint shop need Ex luminaires?
No, only the areas classified as a zone. The rest of the hall can be lit by ordinary industrial luminaires, which are cheaper. At Malieb, 51 of the 266 luminaires were Ex-rated.
What does the marking II 2G Ex … IIC T4 Gb mean?
Group II is for surface installations (not mines), category 2 for zone 1, G for gases and vapours (D for dust), IIC is the most demanding gas group including hydrogen and acetylene, T4 means a maximum surface temperature of 135 °C, and Gb is the protection level for zone 1. Details are in our article on Ex product markings (in Slovak).
Can Ex lighting be dimmed or fitted with an emergency module?
Yes. LENA Ex is available to order with DALI dimming or an emergency module, or we can supply the stand-alone LENA Ex emergency luminaire with a LiFePO4 battery, which stays lit for 3 hours after a power failure and has a self-test function.
How much does lighting for explosive atmospheres cost?
Ex luminaires cost more than ordinary industrial ones, so what matters is how much of the plant is classified as a zone. You get the exact price together with the savings and payback after a site survey and a DIALux calculation.
What warranty do you provide?
5 years on VULCAN, LENA Ex and FOX luminaires, 2 years on the emergency module and battery.
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