Explosion-Proof Components Guide

Explosion-Proof Components Guide

CC-1494A 3

An extensive lineup of CKD explosion-proofCKD offers the best explosion-proof system configuration for use in explosion-proof
atmospheres, including intrinsically safe, explosion-proof, and master valves, to suitvarious applications.

System configuration
Intrinsic safety
Explosion-proof systems

Dangerous zones (Zone 1, 2)

components
JPEx

Zone 0 Zone 1 Zone 2
Can beused in
Zone0

Can beused inZone1

Can beused in
Zone2

International
explosion-proof(IECEx)

Japan Explosion-Proof
CertificationRegion
Japan

GB Standard
Certification
RegionChina

CCC Standard
Certification
RegionChina

ATEX COMMAND
AUTHENTICATION
RegionEuropeKOSHA Standard
Certification
RegionSouth Korea

TSAuthentication
RegionTaiwanAir piping

Non-dangerous zones
Zener barrier

Electric wiring
Short air piping for easy
installation! Easy to installcompact valves!

1
PLC
Class A grounding

SystemInsulating barrier

Solenoid valve
Actuator
installation
Responsivity
space

Air Piping

2
Grounding not required

1

Short

2

Short

3

Short

4

Long

5

Long

Pressure / Explosion proof systems
Simple system configuration
without barriers!

3

Master valveSystems using non-explosionproof solenoid valves

Various communication andoptions are available asstandard products.

Non-explosion-proof solenoid valve(For master valve operation)

4

Pipe length often
exceeds 10 m

52

Non-explosion-proof
solenoid valve: Excellent,: Good,:Conditional

3Intrinsic safety explosion-proof Valve

Variety of valve options

Intrinsic safety explosion-proof
For details of each product, refer to the CKD website (https://www.ckd.co.jp/en/).

Pilot operated 3, 5-port valve

4GD/E EJ

Certification Region: Japan (JPEx)

Zone 1 Zone 2

JPEx

Prevents manual misoperation Standard

Operation indicator

Manual override has a protective cover.

Pressurization status is indicated by an indicator that operates only withair pressure. Contributes to improved maintenance of solenoid valves.

In-stop valve spacer

Air supply spacer

Air can be stopped for each valve. Valves can bereplaced individually without stopping production
line operation.

Air can be supplied at different pressures for each valve.
Ideal for adjusting the thrust of cylinders by increasing ordecreasing the pressure of individual valves.

Ex ib C T4 GbSpecsCylinder bore size: up to ø160
Working pressure range: 0.2 MPa to 0.7 MPa
Degree of protection: IP67
Voltage : 12 VDCFeatures

 ealizes the smallest explosion-proof class valve
Rwidth of 10 mm.
4 sizes: 10 mm, 15mm, 18mm, and 23.5mm.
Rich lineup from space-saving to large flow rate
High durability of 50 million cycles
Max. No. of manifold stations: 15 to 20* Differs depending on solenoid valve size, DIN rail or direct mount ineup includes 2 built-in 3-port valves. TwoL
single acting actuators can be driven by onevalve. Contributes to a significant reduction in thenumber of manifolds.

Pilot operated 3, 5-port valve

4GD/E EA

Certified Region: Europe (ATEX) / International (IECEx)

Zone 1 Zone 2
Ex ib C T4 Gb
SpecsFeatures

2G Ex ib C T4 Gb
Cylinder bore size: up to ø160
Working pressure range: 2 to 7 bar
Degree of protection: IP67
Voltage: 12 VDC
 ealizes an explosion-proof minimum class valve
Rwidth of 10mm.
4 sizes: 10 mm, 15mm, 18mm, and 23.5mm.
Rich lineup from space-saving to large flow rateG thread standard complianceHigh durability of 50 million cycles
Max. No. of manifold stations: 15 to 20(R1)5(P)1(R2)35(R1)
1(P)
3(R2)

5 4 1 2 3
(R1) (A) (P) (B) (R 2)
aP(A)4(B)2* Differs depending on solenoid valve size and direct mount ineup includes 2 built-in 3-port valves. TwoL
single acting actuators can be driven by onevalve. Contributes to a significant reduction in thenumber of manifolds.

Pilot operated 3, 5-port valve

4GD/E EX

Exhaust spacer*

Exhaust check valve*Individual exhaust prevents single acting cylinder misoperation.

Equipped as standard with both metal base andresin block. (4G*1 to 4G*3 EJ compatible)

Certification Region:
China (NEPSI, CCC)/International (IECEx)/Korea (KOSHA)/Taiwan (TS)

Zone 1 Zone 2SpecsFeatures

Ex ib C T4 Gb
5 4 1 2 3(R1)(A) (P) (B)(R2)

Cylinder bore size: up to ø160
Working pressure range: 0.2 MPa to 0.7 MPa
Degree of protection: IP67
Voltage : 12 VDC
 ealizes an explosion-proof minimum class valve width of 10mm.
R4 sizes: 10 mm, 15mm, 18mm, and 23.5mm.
Rich lineup from space-saving to large flow rate
High durability of 50 million cycles
Max. No. of manifold stations: 15 to 20

R 1R 2Air supplyExhaust* W hen using the ABR connection for the valve switching position classification, the exhaust spacer is recommended.
(When using an ABR connection with a malfunction protection valve, it is more difficult for the actuator to be actuated by external forces.)* Differs depending on solenoid valve size and direct mount ineup includes 2 built-in 3-port valves. TwoL
single acting actuators can be driven by onevalve. Contributes to a significant reduction in thenumber of manifolds.
45

Intrinsic safety explosion-proof BarrierBarrier

Intrinsic safety explosion-proof
For details of each product, refer to the CKD website (https://www.ckd.co.jp/en/).

Certification Region: Japan/International(IECEx)/Europe (ATEX)/China (NEPSI,CCC) / Korea (KOSHA)/Taiwan (TS)

Zener barrier

Z728 1CH
Manufacturer: Pepperl+Fuchs Inc .
Refer to the Pepperl+Fuchs Inc. catalog for detailed specifications.

JPEx

Insulating barrier (intrinsic safety explosion-proof structure)

D5048S 1CH[Ex ia] C

Supply source: IDEC Co., Ltd. (Manufacturer: G.M.I)
Refer to the catalog of IDEC or G.M.I. for detailed specifications.

* Also available from CKD.
Intrinsic safety circuit max. voltage Uo:28V
Intrinsic safety circuit max. current Io:93mA
Intrinsic safety circuit max. power Po:0.65W
Intrinsic safety circuit allowable capacitance Co:0.083 μF
Intrinsic safety circuit allowable inductance Lo:3.05mH
Operating ambient temperature range: -20 to 60°CCurrent limiting resistance: 300 Ω

Certification Region:Japan/International(IECEx)/Europe (ATEX)/China (NEPSI,CCC) / Korea (KOSHA)/Taiwan (TS)

Zener barrier
2CH

Manufacturer: Pepperl+Fuchs Inc .
Refer to the Pepperl+Fuchs Inc. catalog for detailed specifications.

JPEx

Certified Region: China (NEPSI, CCC)

[Ex ia Ga] C[Ex ia Da] C

Supply sources:Bei ji an
Refer to the Bei ji an catalog for detailed specifications.

* Also available from CKD.
Intrinsic safety circuit max. voltage Uo:28V
Intrinsic safety circuit max. current Io:93mA
Intrinsic safety circuit max. power Po:0.65W
Intrinsic safety circuit allowable capacitance Co:0.083 μF
Intrinsic safety circuit allowable inductance Lo:3.05mH
Operating ambient temperature range: -20 to 60°C
Current limiting resistance: 301 ΩGuide to max. cable length between barrier and valve
TypeBarrier

Zener barrier 1CH
Zener barrier 2CH
Insulating barrier 1CH type

Z728
Z779
D5048S

0.5 mm2
500m
500m
200m

Cable size
0.75 mm2
0.9 mm2
700m
800m
700m
800m
300m
400m

1.25 mm2
1000m
1000m
500m

Recommended barrier
TypeMTL7728KFDO-SD2-Ex1.1045
MTL5525

Manufacturer
Cooper Industries
Pepperl and Fuchs
Cooper Industries

Specs

Insulating barrier (intrinsic safety explosion-proof structure)*1: The cable length is a guide. Check the specifications of the cable to be used.
*2: The above calculations are based on the low power instrumentation cable JKPEV.
*3: Maximum cable length at 20°C. Note that the maximum cable length changes depending on the operating conditions such as ambient temperature.

6

Intrinsic safety circuit max. voltage Uo:24.8V
Intrinsic safety circuit max. current Io:108mA
Intrinsic safety circuit max. power Po:667mW
Intrinsic safety circuit allowable capacitance Co:0.113 μF
Intrinsic safety circuit allowable inductance Lo:1.42mH
Operating ambient temperature range: -40 to 70°C
* If the output voltage of the control component fluctuates significantly, consider
using an insulating barrier with stable output voltage.

EXDO-11 1CH[Ex ia] C
SpecsInsulating barrier 1CH type[Ex ia] C
SpecsInsulating barrier (intrinsic safety explosion-proof structure)* Also available from CKD.

Type
Zener barrier 1CH type

JPEx

* Also available from CKD.
SpecsZ779

Certification Region: Japan/International(IECEx)/Europe (ATEX)/China (NEPSI,CCC) / Korea (KOSHA)/Taiwan (TS)EXDO-22 2CH

Intrinsic safety circuit max. voltage Uo:28V
Intrinsic safety circuit max. current Io:93mA
Intrinsic safety circuit max. power Po:0.65W
Intrinsic safety circuit allowable capacitance Co:0.05 μF
Intrinsic safety circuit allowable inductance Lo:2.4mH

Certified Region: China (NEPSI, CCC)

[Ex ia Ga] C[Ex ia Da] C

Supply sources:Bei ji an
Refer to the Bei ji an catalog for detailed specifications.

* Also available from CKD.
Specs

Intrinsic safety circuit max. voltage Uo:28V
Intrinsic safety circuit max. current Io:93mA
Intrinsic safety circuit max. power Po:0.65W
Intrinsic safety circuit allowable capacitance Co:0.05 μF
Intrinsic safety circuit allowable inductance Lo:2.4mH

Certification Region
JPEx
JPEx,ATEX,IECEx,NEPSI
JPEx

7

Intrinsic safety explosion-proof With CKD Solenoid valves 1/2 and barriers 1/2
For details of each product, refer to the CKD website (https://www.ckd.co.jp/en/).

Dangerous Zones (Zone 1, 2)

SINGLE

Non-Dangerous Zones

Air operated valve (single acting)Solenoid valve

Solenoid valve

8 stations

8 stations

8 stations

SINGLE

PLC

DUAL

Solenoidvalve
spaceWith many electric wiring andair piping, the control
panel becomes large.

Barrierspace
Air piping
work
hours

DUAL

4 stations

8 stations

Electricwiring workhours

4 stations: Excellent,: Good,:Conditional

Valves and barriers
reduced in half !
A smaller control panel !

Air piping
Electric wiring

Solenoid valveBarrier

Two single acting actuators can be controlled with one manifold station.
Solenoid valves can be installed even in narrow spaces.

2CH type barrier that can drive two solenoid valves with one barrier is available.
Barrier installation space is reduced by half.

Two 3-port valves integrated specifications

2CH

1CH

It can also be connected to a 1 ch barrier. Refer to the barriers on pages 6 and 7 for details.
89Intrinsic safety explosion-proof Input component system for use in Zone 1, 2
Check the working conditions of the barrier switch.

For details on each product, refer to the CKD website (https://www.ckd.co.jp/en/).

Dangerous Zones (1 and 2)

Non-Dangerous Zones

Zone 1 Zone 2

Cylinder switch

Barrier (intrinsic safety explosion-proof structure)

Explosion-proof specifications are not available for discrete cylinder switches.
HoweverW hen using it in Japan, check that the specifications conformto those of IDEC's EB9Z-A relay barrier connection switch.
W hen used outside Japan, the product can be used as a simple
components in a certified Region of IDEC EB3C (relay barrier).

Explosion-proof performance [Ex ia Ga] IIC

International IECEx

South Korea KCS

Specifications

North America FM / UL / c-UL

TaiwanTSEurope

CE / ATEX / UKCA

Japan

DEKRA

China

Ex-CCC

Switch type2-wire reed

Indicator lamp

None

Load voltage

12 VDC / 24 VDC

Load current

50 mA or less

Certification Region

Applicable cylinder

CMK2

LCR

LCG

SW-T5

UCA2: Lead wire direction

H: Straight (photo)
V: L-shaped
SCG

SCM

SSD2

Pressure switch

SSD

STG

Zone 1 Zone 2

Explosion-proof specifications are not available for discrete pressure switches.
HoweverWhen using it in Japan, check that the specifications conformto those of IDEC's EB9Z-A relay barrier connection switch.
When used outside Japan, the product can be used as a simple
components in a certified Region of IDEC EB3C (relay barrier).

PLCGeneral
purposeinstallation

EB3C

Specifications
Working fluid

Compressed air

Set pressure

0.1 to 0.6 MPa

Relay barrier (intrinsic safety
explosion-proof structure)

Max. working pressure 1.0 MPa

APS-6D-W-FL459606

FR unit connection image

FR unitConnection

P4100- -W-FLA79598

Compliant with International Explosion-Proof Guidelines 2015Ex, 2020Ex and technical standards.
A wide variety of models are available, from 1-circuit to 16-circuit units.
The 16-circuit models are available with a connector type for easy connection to PLCs.
No grounding is required for the DC power supply type.
Relay output and transistor output (sink/source) are available on the non-intrinsic safety circuit side.
Refer to the catalog, instruction manual, etc., issued by IDEC Co., Ltd. for the working conditions
when connecting a switch and relay barrier.

Purchases can be made from IDEC Co., Ltd.
Refer to the IDEC catalog for detailed specifications.

: Port size (ø8, ø10, ø15)

1011

Pressure and Explosion-proof

Master valve
For details of each product, refer to the CKD website (https://www.ckd.co.jp/en/).

Pilot operated 5-port valve

4F**0E*

Certification Region:
Japan/China (NEPSI, CCC)/Korea (KOSHA)/Taiwan (ITRI)

Zone 1 Zone 2SpecsFeatures

Direct acting 2-port valve

AB41EX4
AB41EX2JPEx

Exd II BT44GA/BR

Specs

Cylinder bore size: up to ø250
Working pressure range: 0.2 MPa to 0.7 MPa
Degree of protection: IP65
Voltage: 12, 24 VDC, 100, 110, 200, 220 VAC
Valve width: 51 mm, 60 mm, 68 mm, 74 mm, 91 mm,Diverse valve lineup of 5 types.
Compatible with outdoor use (IP65)
Selectable electric wire cable diameter range: ø7.5 to ø13.5
Max. No. of manifold stations: 10

Certification Region:
Japan/China (NEPSI, CCC)/Korea (KOSHA)

Zone 1 Zone 2

Compatible cylinder bore size up to ø100
Working pressure range
Main pressure:
0 MPa to 0.7 MPa				Features

Compatible with outdoor use (IP65)
Selectable electric wire cable diameter range: ø7.5 to ø13.5*2 position single:(0.6 × main pressure + 0.06) to 0.7MPa

Features
Valve width: 10mm, 15mm, 18mm.
Diverse lineup of 3 types of valves.
High durability of 100 million cycles

Exd II BT4Working fluids: Air/Low vacuum/Water/Kerosene/Oil
Actuation: NC (Normally Closed)
Port size: Rc1/4, 3/8
Working pressure differential: 0 to 5 MPa
Voltage: 12, 24, 48, 100 VDC, 100, 200 VAC*2-position single: 0.2MPa to 0.7MPa

Pilot signal pressure: 0.2 MPa to 0.7 MPa

JPEx

SpecsZone 0 Zone 1 Zone 2

Pilot operated 3, 5-port valve* China (NEPSI, CCC) certified products are the AB4*E2/E4 Series.

Direct acting 3-port valve

AG41EX4
AG43EX4
AG44EX4

Certification Region:
Japan/China (NEPSI, CCC)/Korea (KOSHA)

Zone 1 Zone 2JPEx

Exd II BT4

SpecsWorking fluids: Air/Low vacuum/Water/Kerosene/Oil
Actuation: Universal, NC pressurization, NO pressurization
Port size: Rc1/4, 3/8
Working pressure differential: 0 to 1.5 MPa
Voltage: 12, 24, 48, 100 VDC, 100, 200 VAC

Features

Compatible with outdoor use (IP65)
Selectable electric wire cable diameter range: ø7.5 to ø13.5* China (NEPSI, CCC) certified products are the AG4*E4 Series.

Pilot operated 2-port valve

AP11EX4
AP21EX4
AP11EX2
AP21EX2

Certification Region:
Japan/China (NEPSI, CCC)/Korea (KOSHA)

Zone 1 Zone 2SpecsFeatures

JPEx

Exd II BT4Working fluids: Air/Water/Kerosene/Oil
Actuation: NC (Normally Closed)
Port size: Rc1/4, 3/8, 1/2, 3/4, 1
Working pressure differential: 0.05 to 1.2 MPa
Voltage: 12, 24, 48, 100 VDC, 100, 200 VAC
Compatible with outdoor use (IP65)
Selectable electric wire cable diameter range: ø7.5 to ø13.5* China (NEPSI, CCC) certified products are the AP**E2/E4 Series.

Pilot kick 2-port valve

ADK11EX4

Certification Region:
Japan/China (NEPSI, CCC)/Korea (KOSHA)

Zone 1 Zone 2JPEx

Non-explosion-proof solenoid valve
Pilot operated 3, 5-port valve

4GA/BRSpecs
Compatible cylinder bore size up to ø160
Working pressure range 0.2 MPa to 0.7 MPa
Degree of protection IP40

Features
Compatible with various communications	EtherNet/IP, DeviceNet, EtherCAT, CC-Link, CC-Link
IE Field Basic, CC-Link IE Field, IO-Link, PROFINET,PROFIBUS-DP
Valve width: 10 mm, 15 mm, 18 mm, 23.5 mm.
Diverse lineup of 4 types of valves.
High durability of 100 million cycles
Responsivity: 12ms and up

Exd II BT4Specs

Working fluids: Air/Low vacuum/Water/Kerosene/Oil
Actuation: NC (Normally Closed)
Port size: Rc1/2, 3/4, 1
Working pressure differential: 0 to 1.0 MPa
Voltage: 12, 24, 48, 100 VDC, 100, 200 VAC

Features

Compatible with outdoor use (IP65)
Selectable electric wire cable diameter range: ø7.5 to ø13.5* China (NEPSI, CCC) certified products are the ADK1*E4 Series.

1213

Reference materials
Explosion-proof performance display example

Explosion-proof
This concept is to prevent explosions of gas vapors due to sparks and high temperaturesgenerated by electrical components in dangerous zones where explosive gas atmospheres
may be generated, and to ensure the safe use of electrical equipment.

Particulates
Zone2

Zone1

Zone0

Zone21

Zone22

123

Pressure and explosion proof

IIEx ib

Ex d2G

Ex ib

II C T4

Zone20Combustible liquid

Components
Category

Japan Explosion-Proof Certification [IECEx, GB]

Category
Code Applications Atmosphere
I MinesMethaneII Plant
Gas / SteamIII Dust
PowderExamples of Dangerous Zones
Gas

Intrinsic safety explosion-proof [ATEX]

Dangerouszone(Gas)

Dangerouszone(Particulates)

Zone 0Zones where explosive atmospheres exist continuously or forZone 20 long periods of time.
(Over 1000 hours/year. *1)

Explanation of Dangerous Zones

Zone 1

Zones where explosive atmospheres may be generated during
Zone 21 normal operation of plants, etc.
(10 to 1000 hours per year. *1)

Zone 2

Areas where explosive atmospheres are not likely to begenerated during normal operation of the plant, etc., and even if
Zone 22they are generated, they will exist only for a short period of time.
(1 to 10 hours/year *1)

Gb

II C T4

Component category
ProtectionZones
Code Component
category
level(Gas / Dust)
1 Category 1 Very high Zone 0 / 20
2 Category 2 High
Zone 1 / 21
3 Category 3 Normal
Zone 2 / 22
G: Gas (Gas) D: Dust

Gb

II B T4

Explosion proof structure
Technical standard Zone Zonetype and code01Pressure and explosion ×proof structure Ex dIntrinsic safety explosionproof structure
×Ex ia, Ex ib

Typical explosive gas group and temperature classGroupTemperature
T1T2
T3class
AcetoneAmmonia
Carbon monoxide
Ethyl acetate
EthanolToluene
ButaneGasoline
II A
PropaneIsoamyl acetate
HexaneBenzeneAcetic anhydride
Methanol
MethaneEthaneAcetic acid
Ethylene
II B
City gas
Ethylene oxide
II C
Hydrogen
Acetylene

T4Zone2T5

Acetaldehyde

Ethyl ether
Carbon disulfide

Protection levelGaComponents with extremely high level of protection, usable in Class 0 Dangerous Zones
GbComponents with a high level of protection, usable in Class 1 Dangerous Zones
GCComponents with an enhanced protection level, usable in Class 2 Dangerous Zones

Related products
ATEX Directive compliant product guide he ATEX Directive compliant products which can beTused in Europe are listed.
C omplete lineup of components including cylinders,solenoid valves, and FR units required for pneumaticsystem configuration.

* 1 Time to generate explosive atmosphere(Catalog No. CC-1563A)
1415

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2024.8