What does Intrinsically Safe (IS) Mean?
Intrinsically safe (IS) is a unique approach to electrical equipment design, where the goal is to make a product that is incapable of ignition under ordinary or hazardous environments. A common technique for achieving intrinsically safe lighting is to use parts and wiring that lack the necessary thermal and electrical energy for combustion.
Intrinsically safe lights are specially designed to withstand extreme heat, electrical surges, mechanical damage, hazardous gasses, and other risk factors. LED lighting fixtures that can resist ignition or explosion under the direst circumstances are certified as intrinsically safe.
High-performance lights are commonly labeled as either IS (intrinsically safe) or EP (explosion-proof lighting). The difference between the two types is a minor one and only slightly affects the light’s application. You can read more about it in a separate section below.
Regardless of the labeling both lighting systems can be adapted to various light fixtures. An IS-certified flood light is the same as a regular flood light, but with a more robust and completely sealed outer enclosure.
Why is Intrinsically Safe LED Lighting so Important?
LED lights have a generous operating range and are typically applicable to most residential and commercial buildings. But for certain high-performance applications, you will need more robust LED lights. Intrinsically safe LED lights cover an important sector of commercial lighting that regular LED lights cannot serve.
Hazardous areas are quite common in industrial work and can often result in serious damage to the workers as well as electronics. PPE (personal protective equipment) and SOP (standard operating procedures) are responsible for worker safety. But electrical equipment such as lighting requires a different approach for safe operations.
Factories are full of corrosive liquids, flammable gasses, and combustible debris that can damage the lights resulting in fires or even explosions. Corroded wiring can cause a spark, mechanical impacts can damage batteries, and heat can ignite or combust some materials.
These dangerous working environments are unfortunately a necessary part of our modern society. And the best way to combat these hazardous locations is to provide proper equipment to workers and install intrinsically safe electronics. Science has advanced LED technology to a point of extreme safety and reliability.
Most high-performance industrial work is also high risk and it’s not possible without the safety of IS lights. Intrinsically safe LED lighting is not just important to the industrial sector it is a necessity.
Why do LED Lights Ignite, Combust, or Explode?
Fires and explosions are very common in industrial work, especially work that deals with dangerous materials. Any time electricity comes in contact with flammable materials or debris the risk for accidents increases significantly. The three most common types of lighting-related fires are as follows.
1 – Ignition
Several raw materials that are processed in industries are quite combustible. Cloth fibers, wood dust, and paper pieces can all easily ignite from nearby heat or electrical discharges.
2 – Combustion
Damaged or corroded wires can easily end up shorting your power supply leading to a small fire. Hazardous workplaces that often deal with flammable liquids or gasses can quickly combust from shorted wiring.
3 – Explosion
Explosions are the most difficult type of hazard to quantify. Explosions can occur as a result of a number of mishaps. A common type of industrial hazard is the dust explosion. The fine dust of combustible materials exposed to sparks or fire will result in a series of quick combustions leading to an explosion.
Other explosions occur from gas leaks in the workplace or due to damaged Lithium-ion batteries.
How are Intrinsically Safe Products Certified?
LED lighting products must comply with region-specific safety standards to qualify for Intrinsic Safety Certification. North America (US & Canada) has a different certification system than the European Union.
US & Canada Certification
The US follows electrical safety certification developed by the NEC (National Electrical Code) which is dependent on three major factors, Class, Division, and Group. Certifications for intrinsically safe lights follow the following pattern.
CL 1, DIV 1, GP A-D
CL stands for Class, DIV for Division, and GP for Group. Occasionally a fourth factor will be added to the end using the letter T for temperature. All Intrinsically safe LED lighting systems should have a Division 1 Rating. While the Class and Group are environment-dependent.
Class
A means of categorizing common flammable material in the operating environment. All hazardous materials are further divided into three classes.
- Class 1 – Flammable gasses
- Class 2 – Combust Dust
- Class 3 – Ignitable Fibers
Division
A categorization based on the likelihood of a hazardous situation occurring in the operating location. There are only two divisions of intrinsic safety.
- Division 1 – Hazard is likely to occur in this location even under normal operating conditions.
- Division 2 – Hazard is not likely to occur in this location unless the operating conditions are uncommon and abnormal.
Group
Groups are a sub-categorization of Classes of flammable materials. The categorization range is from A to G, and each group has detailed names of flammable or combustible materials.
- Group A to B – Combustible gasses
- Group C to D – Flammable Chemicals
- Group E – Combustible Aluminum & Magnesium Alloy Dust.
- Group F – Carbon-based Combustible Dust.
- Group G – Non-Metal and Non-Carbon based Combustible Dust such as Wood, Plastics, Starch, etc.
European Union Certification
ATEX (Appareils destinés à être utilisés en ATmosphères EXplosibles) is a standard safety certification in Europe. The original French term translates to “Equipment intended for use in explosive atmospheres”. This standard is more complicated as it uses a more detailed breakdown for the hazardous locations where a LED light is deployed.
Environment Group
This grouping is based on the environment where the electrical equipment is expected to be deployed.
- Group I – Mines with Methane present.
- Group II – Non-Mines with Explosive Gas present.
- Group III – Non-Mines with Methane or Combustible Dust.
Intrinsically safe lighting systems should be rated for Group I or II.
Hazard Category
Hazard categorization is based on the consistent presence of combustible materials.
- Category 1 – Continuously Present Combustible Dust or Gas.
- Category 2 – Occasionally Present Combustible Dust or Gas.
- Category 3 – Rarely Present Combustible Dust or Gas.
Intrinsically safe lighting systems should be rated for Category 1 or 2.
Material Category
A categorization for the type of explosive/combustible material present in the environment.
- Category G – Flammable Gas
- Category D – Dust Particles
Protection Type
A letter grade is assigned to the electrical equipment for its resistance to certain types of ignition.
- Type i – Intrinsically Safe
- Type e – Increased Safety
- Type d – Flameproof
- Type n – Sealed Equipment
- etc.
Intrinsically safe lighting systems can often have two or more of these protection grades printed on the fixtures.
Fault Analysis
This section categorizes the conditions for ignition.
- Type a – Equipment can withstand Two Faults before ignition.
- Type b – Equipment can withstand only One Fault before ignition.
- Type c – Equipment can potentially ignite under normal operations.
Atmosphere
Atmospheric groups define the exact hazardous material present in the operating environment.
- Group I – Methane
- Group II – Combustible gasses
- Group III – Combustible Dust and Particles
Intrinsically Safe vs. Explosion Proof Lights
High-performance lights are commonly labeled as either IS (intrinsically safe) or EP (explosion-proof lighting). The difference between the two types is a minor one and only slightly affects the light’s application.
Explosion Proof Lighting
Explosion-proof lighting refers to a special type of lighting technology that is designed to contain an explosion. These lights differ from IS lights based on two important attributes.
- Lighting Fixture Design
- Power Consumption
A light fixture or luminaire is a complete lighting unit made up of a light source, enclosure, and minor electronics. Here the light source can be incandescent bulbs or LEDs (light emitting diodes). The enclosure can range from a small outer plastic casing to a complexly designed lamp stand.
Intrinsically safe lights are designed to avoid explosions in the first place through well-sealed fixtures and a limited power supply. By this definition, all IS lights can also be called explosion-proof.
But Explosion proof lighting is designed in anticipation of a potential explosion during standard operation. As such these lights have specialized enclosures that contain the explosion and keep it from spreading to other areas. Hence EP/Ex lights are a more accurate example of the term explosion-proof.
It should be noted that explosion-proof lights are only safe from an internal explosion caused by the LEDs or the circuit. They are still susceptible to an external explosion caused by other triggers in the environment.
Do You Even Need Explosion Proof Lighting?
Regular IS lights run on considerably lower power and have a lower light output. For applications where high-intensity discharge lights are a necessity, you can turn to explosion-proof lighting systems. These EP lights run at higher wattages and provide a higher brightness compared to the light output of IS lights.
Explosion-proof light fixtures also cost significantly more than intrinsically safe light fixtures. So unless you can justify the cost, EP lights are not recommended.
7 Key Considerations Before Buying Intrinsically Safe Lighting
For most lighting applications in hazardous areas, you do not need additional guidelines or tips. But understanding the basics of IS lighting systems can help you further optimize your factory lighting, increase occupational safety, and save some installation costs.
Here are our top seven picks for things to consider before buying intrinsically safe lights.
1 – Installation Location
Location cannot be understated when it comes to IS lights. After all, it’s your location (environment) that determined the feasibility of IS lights in the first place. Some outdoor lighting systems do not need IS or EP lights even if the environment is hazardous.
Hazardous is a broad term that can include trace amounts of flammable gasses or metal debris. If you only deal with the occasional metal dust you can achieve the same level of occupational safety by installing shop vacs (industrial grade vacuums) near the machinery instead of rewiring your entire factory.
Intrinsically safe light fixtures are a very important part of industrial work but a typical factory will only require these lights to be deployed in certain areas. The rest of the factory can still use commercial lighting options like a standard IP-rated spot or flood light.
2 – Power Consumption
Power consumption for intrinsically safe lights is slightly different from commercial offerings. IS lights typically consume less wattage and provide less luminance, resulting in the need for additional lighting fixtures to compensate for the loss in lumens.
If you require explosion-proof lighting in some areas of your workplace then you will need to consider the different power requirements for your EP high-intensity discharge lights from your other IS lights.
3 – Wiring Requirements
Wiring for intrinsically safe or explosion-proof lighting systems is a more complicated process than regular LED light wiring. The wires need to be properly shielded and covered to avoid mechanical damage and potential accidents.
All your wiring will need some sort of intrinsically safe barrier around it for added protection. These barriers can come in the form of thicker insulation or additional seals and conduits. Keep in mind that explosion-proof lights that consume extra power will need extra strong wire protection as well.
4 – Light Source
The light source for IS lights is always a LED (light emitting diodes) unit. LEDs have considerably higher energy efficiency compared to other light sources. CFL and Incandescent bulbs produce a lot more heat and that excess heat can be very difficult to manage.
Poorly managed heat output can easily lead to lighting failures. Incandescents work by heating a thin metal wire to an absurd temperature where the wire starts to glow and generate light. The glass enclosures for these bulbs are quite fragile and the slightest damage can lead to ignition.
Aside from their exceptional energy efficiency, LEDs are also quite small. The smaller footprint allows for more versatility in the fixture design. Unlike traditional lighting, LEDs can have a thick robust enclosure and still maintain an overall thinner profile.
5 – Fixture Options
Intrinsically safe is a lighting certification and fixture design technique that is compatible with all types of lighting fixtures. Size and shape limitations barely exist in this industry and the options for fixture design are very diverse.
Common examples of IS lights include helmet-mounted safety lights. These lights are commonly used by minors who can only carry a compact and lightweight fixture with them. Most lighting manufacturers will offer IS lighting solutions for their entire product lineup.
6 – Maintenance Considerations
Maintenance is an unavoidable aspect of electronics. Even high-quality and completely sealed LED lights will eventually require some minor maintenance. Since IS lights are deployed in hazardous environments, maintaining them can be a real challenge.
Maintenance of IS lights is often as simple and quick as commercial LED lighting. However, since IS lights are sealed and enclosed in a robust fixture. Some extra steps are occasionally needed. We strongly urge that you turn off the main power supply before working on IS light maintenance, especially in the case of EP lights.
Of course, some maintenance will also require the factory to be temporarily shut down. Ideally, your lighting and machinery maintenance should be planned together to minimize the loss of working hours.
7 – Cost Analysis
Cost analysis for intrinsically safe light fixtures might seem simple at first. But it actually has a few hidden elements that can lead to increased costs, you’re not careful. The most obvious contributor to cost is the light fixtures themselves. You can control this aspect by carefully estimating the required number of fixtures beforehand.
But a hidden cost to IS lighting is the wiring. As discussed previously, IS lights need properly sealed wires and cables to function properly. And for large factories, this cost can quickly start to creep up.
Why Buy Intrinsically Safe Lighting from RC Lighting?
RC Lighting is a long-term manufacturer and supplier of high-quality architectural LED lighting solutions. We have a diverse and extensive catalog of Indoor and Outdoor Lighting options. Substandard lighting products lack the necessary quality control for high-risk environments and can quickly turn into a safety nightmare. Intrinsically safe lights are a matter of life and death for your workers. You should only buy safety products, such as intrinsically safe lighting from a reputable and trustworthy supplier.
We recommend our Recessed LED Downlights series for your workplace lighting.
Conclusion
Safety lighting can be a difficult project to manage. There are several complex terms and standards for intrinsically safe lights that often contradict one another. Navigating this lighting field can be a challenge for beginners as well as novices. But careful research and preparation can help you avoid potential pitfalls in your lighting endeavors.
RC Lighting has a long history of supplying quality products that comply with several international health and safety standards. You can never go wrong when buying IS lights from an established brand like RC Lighting. Contact us Now!
