Yes, industrial LED lighting can be used in potentially explosive environments, but only if the luminaires have a valid ATEX certification. Standard LED luminaires are prohibited in these zones, regardless of their IP rating or build quality. In this article you will find answers to the most frequently asked questions about ATEX lighting: from zone classifications and technical operation to certification markings and the difference with IECEx.
What are ATEX zones and what lighting requirements apply?
Not every industrial environment is the same when it comes to explosion risk. ATEX zones are areas where an explosive atmosphere can occur due to the presence of flammable gases, vapors, mists, or dust. The European ATEX directives divide these areas into zones based on how often and how long an explosive atmosphere is present,and that classification directly determines which lighting you are allowed to use there.
The zone classification determines which protection level is required:
- Zone 0 / Zone 20: Explosive atmosphere is continuously or for long periods present. The highest level of protection is required (category 1).
- Zone 1 / Zone 21: An explosive atmosphere occurs occasionally during normal operating conditions. Category 2 equipment is required.
- Zone 2 / Zone 22: Explosive atmosphere is rare and of short duration. Category 3 equipment is permitted.
Zones 0, 1 and 2 relate to gases and vapours. Zones 20, 21 and 22 are intended for environments with combustible dust, such as in the food industry or during the storage of fine powder. Luminaires in each zone must be demonstrably approved for those specific conditions.
How does explosion-proof LED lighting work technically?
The principle may be surprising: explosion-proof lighting does not prevent an explosion, but ensures that the luminaire itself can never act as a source of ignition. This is achieved through specific construction methods that isolate the electrical components from the surrounding atmosphere.
The most commonly used protection concepts are:
- Ex d (pressure-resistant enclosure): The housing is constructed so solidly that an internal ignition cannot propagate to the outside.
- Ex e (enhanced safety): Electrical connections and components are designed to prevent sparking and overheating.
- Ex i (intrinsic safety): The electrical energy in the circuit is so low that ignition is physically impossible.
- Ex nA (non-sparking): Used in Zone 2, where the circuit does not produce sparks under normal conditions.
In addition to the protective enclosure, temperature control is crucial. Every ATEX luminaire has a maximum surface temperature, expressed as a temperature class (T1 through T6). This limit must never be exceeded, as the surrounding atmosphere could otherwise still ignite. LED technology has an advantage over traditional light sources in this regard: LEDs produce significantly less heat while providing the same level of light.
What do the ATEX certification markings on a luminaire mean?
That series of letters and numbers on an ATEX luminaire may seem cryptic at first glance, but it is actually a coded description of the approved operating environment. They indicate at a glance for which zone, gas type, and temperature class the luminaire is certified. Correctly interpreting these markings is essential when selecting the right lighting.
A typical ATEX marking looks like this: II 2G Ex db IIC T6 Gb. The parts mean:
- II: Apparatus group II, for surface industries (not for mines).
- 2G: Category 2, suitable for Zone 1 and Zone 2, with G for gas.
- Ex: An indication that this pertains to explosion protection.
- db: Protection concept flameproof enclosure (d) with increased safety (b).
- IIC: Gas Group. IIA is for propane, IIB for ethylene, and IIC for hydrogen and acetylene (the most explosive).
- T6: Maximum surface temperature of 85 °C.
- GB: Protection level for Zone 1 applications.
For combustible dust environments, a D appears instead of G (for example, 2D, IIC T135 °C Dc). It is of great importance that the marking exactly matches the requirements of the relevant zone. IP and IK ratings are complementary to this, but never replace the ATEX marking.
Which industrial sectors use ATEX lighting the most?
ATEX lighting is mandatory in all sectors where flammable substances are present during production, storage, or transport. This involves a wide range of industries, from petrochemicals to food processing.
The sectors with the highest demand for ATEX-certified LED luminaires are:
- Oil and gas industry: Refineries, drilling rigs, and pipeline terminals constantly work with flammable gases and liquids.
- Chemical industry Production sites involving solvents, acids, or reactive substances almost always fall under ATEX regulations.
- Offshore and maritime operations: Ships and platforms with fuel tanks or gas installations require certified offshore lighting.
- Harbors and terminals: Storage and transfer of flammable liquids and gases in tank farms and loading stations.
- Food industry and pharmaceuticals: Fine organic dust such as flour, sugar, or pharmaceutical powders can form explosive dust clouds (Zone 21/22).
- Mining Underground mining with methane gas requires the highest ATEX category.
Local ATEX zones can also be present in heavy manufacturing and recycling companies, for example near spray booths, paint storage areas, or installations with flammable refrigerants.
What is the difference between ATEX and IECEx certification?
Both systems focus on explosion-proof equipment, but the geographical scope differs significantly. ATEX is mandatory within the European Union and is based on EU directives 2014/34/EU and 1999/92/EC. IECEx is an international system of the International Electrotechnical Commission and is recognized outside of Europe, including in Australia, Canada, and the Middle East.
The technical requirements of both systems are largely comparable, but the certification procedures and markings differ. A luminaire with ATEX certification does not automatically comply with IECEx requirements, and vice versa. For projects outside Europe, it is therefore necessary to check which certification is required locally.
In practice, many manufacturers opt for dual certification so that luminaires can be used both in Europe and internationally. This is particularly relevant for companies operating in the port and terminal sector with internationally operating installations.
When is a standard IP65 luminaire not sufficient in an industrial environment?
An IP65 rating says something about protection against dust and water jets, but nothing about the risk of ignition. In ATEX zones, an IP65 luminaire without corresponding ATEX certification is legally insufficient and downright dangerous.
But even outside ATEX zones, there are situations where a standard IP65 luminaire falls short:
- Extreme temperatures In environments with heat above 50 °C or cold down to -25 °C, standard luminaires perform unreliably or fail completely.
- Aggressive corrosion: Sea air, acids, lyes or chemical vapors rapidly attack ordinary aluminum housings. For these environments, corrosion-resistant lighting made of stainless steel or specially coated material is necessary.
- Mechanical shocks and vibrations: Heavy machinery, cranes, and vehicles cause vibrations that damage standard luminaires. A high IK rating is therefore required.
- High-pressure washing: In environments where equipment is regularly cleaned with high-pressure washers, IP65 is not sufficient. IP66 or IP67 is then minimally required.
The correct choice of luminaire always starts with a thorough analysis of the environmental conditions, not just the IP rating. Sound knowledge of standards, zone classifications, and material selection is indispensable in this regard.
Real-world example: DFDS – Terminal lighting in Vlaardingen
The project at DFDS Seaways in Vlaardingen clearly demonstrates how ATEX requirements in a real port environment affect every design choice. The terminal handles roll-on/roll-off freight and operates day and night, which had a direct impact on the planning and execution of the lighting installation. Downtime was not an option: luminaires had to be installed and commissioned without disrupting ongoing port operations.
The technical challenge lay in the combination of factors: highly corrosive sea air, the presence of fuel-related zones on the site, and the need for uniform lighting levels across large areas with varying driving routes. Luminaires with the appropriate ATEX zone classification for the relevant parts of the site were chosen, made of corrosion-resistant material to guarantee longevity in the salty environment. The light distribution was specifically tailored to the traffic lanes and loading bays so that operators and vehicles could work safely without glare.
What this project confirms connects seamlessly with the core of this article: ATEX certification is a necessary condition, but not the only one. The luminaire must also be able to withstand the specific local environmental conditions, from corrosion and mechanical stress to thermal requirements. More comparable cases can be found at DFDS project page.
How JEL Products Helps with ATEX Lighting and Explosion-Proof Environments
JEL Products supplies explosion-proof LED lighting for the most demanding industrial environments, including ATEX-certified luminaires for applications in zones with flammable gases, vapors, and dust. Our approach goes beyond simply supplying a luminaire: we provide guidance throughout the entire process, from zone classification and lighting design to installation and commissioning.
What sets JEL Products apart in ATEX applications:
- Certified luminaires for various ATEX zones, including applications with aggressive chemical exposure
- Stainless steel versions for environments with extreme corrosion combined with explosion hazard
- Technical advice on the correct zone classification and certification requirements per location
- ISO 9001 and VCA** certified working method for safe installation and delivery
- Experience in sectors such as offshore, chemical, ports, and heavy industry
Do you have a project that requires explosion-proof lighting, or do you want to know if your current installation complies with the applicable ATEX standards? Please contact JEL Products for a no-obligation technical discussion.