ATEX compliance in industrial environments can often seem like a complex and costly hurdle, especially when it comes to equipment used in potentially explosive atmospheres. Zone 2, in particular, presents its own unique set of challenges, as it requires special precautions, yet for most of the time, it can seem just like any other non-hazardous part of the factory. This article explores how Zone 2 can be less painful to manage, particularly through the use of IP67 Remote I/O solutions, which can reduce both cost and complexity without compromising safety. What is Zone 2, and why is it challenging? Before diving into solutions, it’s helpful to understand the context of Zone 2. ATEX zones are classification systems used to define areas where explosive atmospheres may occur due to the presence of gas or dust. For gas, the zones are defined as follows: Zone 0: The highest risk zone, where explosive atmospheres are continuously present, or present for long periods (more than 1000 hours per year). Zone 1: A moderate-risk zone, where an explosive atmosphere is likely to occur under normal operation (10 to 1000 hours per year). Zone 2: The lowest risk, where explosive atmospheres only occur under abnormal conditions (less than 10 hours per year). Similarly, dust zones (20, 21, and 22) 32 | Plant & Works Engineering www.pwemag.co.uk April/May 2025 Handling & Safety Matters Focus on: Health & Safety Managing Zone 2 environments can be complex and costly, requiring careful attention to safety and compliance. PWE explores how IP67 remote I/O solutions can simplify maintenance, reduce costs, and enhance operational efficiency in these areas. Simplifying the challenges of Zone 2 with IP67 Remote I/O solutions correspond to different levels of risk associated with explosive dust clouds. Zone 2, while lower risk compared to Zones 0 and 1, presents a unique challenge because, for more than 99.9% of the time—approximately 8750 hours per year—the area behaves like any other non-hazardous environment. Yet, stringent precautions must be observed when equipment is used, maintained, or installed in these areas. These measures, while essential for safety, incur higher costs and extended maintenance times. While no-one thinks that special precautions in the higher zones are not required, to use an analogy, of a domestic kitchen with a situation similar to a Zone2, e.g. a gas leak, would you search for the leak in your house with a match? So how can we make it less painful? Making Zone 2 management more efficient In an ideal world, the risk would be eliminated entirely, and the area could be declassified, removing the need for ATEX compliance altogether. However as this is rarely feasible or practical, what else can we do? The use of non ATEX equipment in a suitable Zone 2 certified enclosure may well reduce the initial cost of the equipment but this is false economy. The more sensible thing to do is to use products designed for use in Zone 2 which don’t require any enclosure, can be mounted directly to the machine and use plug-in connectors everywhere. This can reduce maintenance costs enormously. The elimination of enclosures makes access far easier, with a gas-free certificate no longer required, to confirm that there is no explosive atmosphere before the cabinet can be opened. The use of quick disconnect connections ensures that a product can be replaced with no subsequent need for extensive electrical testing. Wiring terminals, as well as being the point of failure when replacing any product, also take far longer to repair. Typically a wiring terminal takes 5 – 15 minutes per connection, requires tools (screwdriver, torque wrench, wire strippers, ferrules) and has a high risk of miswiring, loose connections and broken wires. A quick disconnect plug and socket takes between 30 seconds and 2 minutes per plug, requires no tools and eliminates misconnections. Solution for Zone 2 One company which offers a comprehensive suite of products that provide solutions for both hazardous and non-hazardous environments is Turck Banner. Its products cover all ATEX zones, with a range of sensors, interconnecting cables, PLCs, and fieldbus solutions tailored specifically for Zone 2. The parent company, Turck, is an industry leader in producing IP67, IP68, and IP69Krated fieldbus products that can be mounted directly onto machines. This capability significantly simplifies machine reconfiguration, as components can be easily relocated between production lines, and tooling changes become more efficient. Products designed for direct machine mounting are exposed to more challenging environmental conditions, such as higher temperatures or physical wear, compared to those housed in enclosures. Turck Banner addresses these concerns by offering rugged products with metal housings and extended
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