Intrinsically safe torches are designed for use in hazardous areas where flammable gases, vapours or combustible dusts may be present. Unlike conventional torches, intrinsically safe lighting is engineered to control potential ignition sources so that the equipment does not introduce an unacceptable ignition risk within the conditions covered by its certification.
This guide explains what makes a torch intrinsically safe, how ATEX hazardous area torches work, what certification means and what to consider when selecting portable lighting for hazardous environments.
An intrinsically safe torch is designed to prevent its electrical or thermal energy from becoming an ignition source within the conditions defined by its certification.
This is achieved through the engineering and assessment of the complete product rather than simply the light source.
Depending on the protection concept, the design can involve controlling:
The purpose is to reduce the possibility that the torch could ignite an explosive atmosphere when operated within its specified conditions.
Important: Intrinsically safe does not mean that every torch can be used in every hazardous area. The individual product’s certification and conditions of use must always be checked.
An intrinsically safe torch works by controlling the energy available within the equipment.
An ATEX intrinsically safe torch is portable lighting equipment that has been assessed and certified for use in specified potentially explosive atmospheres under the applicable ATEX requirements.
The complete marking and certification information should be checked to establish the conditions under which the equipment can be used.
These can include:
Hazardous areas are classified according to the likelihood and duration of an explosive atmosphere being present.
| Zone | General Meaning | Torch Selection |
|---|---|---|
| Zone 0 | Explosive gas atmosphere is present continuously, for long periods or frequently. | Equipment must have the appropriate certification for Zone 0. |
| Zone 1 | Explosive gas atmosphere is likely to occur occasionally during normal operation. | Use appropriately certified hazardous-area lighting. |
| Zone 2 | Explosive gas atmosphere is not likely during normal operation but may occur briefly. | Equipment must still meet the applicable hazardous-area requirements. |
When selecting hazardous-area lighting, two certification systems you may encounter are ATEX and IECEx.
ATEX: is the European regulatory framework for equipment and protective systems intended for potentially explosive atmospheres.
IECEx: is an international certification system based on applicable IEC standards for equipment used in explosive atmospheres.
Neither term on its own provides enough information to determine whether a torch is suitable for a particular application.
The complete certification marking needs to be considered.
Hazardous-area equipment can carry detailed certification markings that communicate important information about the equipment’s intended use.
Depending on the product, these markings may identify:
Selecting the correct intrinsically safe torch involves more than choosing the brightest available model.
Identify the zone and hazardous atmosphere where the torch will be used.
Check the complete ATEX and/or IECEx certification against the application.
Confirm that the equipment’s maximum surface temperature is appropriate.
Consider the required protection against dust and water for the application.
Consider lumens, beam pattern and beam distance according to the task.
Consider battery type, expected operating time and charging requirements.
| Feature | Why It Matters |
|---|---|
| ATEX / IECEx Certification | Helps establish suitability for specified hazardous-area applications. |
| Zone Classification | Determines the type of hazardous atmosphere the equipment is designed for. |
| Temperature Class | Defines the maximum surface temperature under specified conditions. |
| IP Rating | Indicates protection against ingress of dust and water. |
| Lumens | Provides an indication of light output. |
| Beam Distance | Helps determine how effectively the torch illuminates objects at distance. |
| Battery / Runtime | Determines how long the torch can operate before battery replacement or charging. |
If your application requires portable lighting for a hazardous area, our range of Intrinsically Safe Torches provides certified Peli Lighting solutions for specified hazardous-area applications.
Explore our range of ATEX and IECEx certified Peli Lighting torches for specified hazardous-area applications.
For applications requiring portable lighting certified for Zone 0 hazardous areas, explore the dedicated range.
Browse portable and temporary lighting solutions for hazardous-area and industrial applications.
Choosing hazardous-area equipment should always begin with the environment rather than the product specification.
A torch with high brightness, long battery life or a rugged construction is not necessarily suitable for a potentially explosive atmosphere.
The correct selection process should be:
Thorne & Derrick supplies intrinsically safe torches and portable lighting for hazardous areas, including ATEX Zone 0, Zone 1 and Zone 2 environments.
When discussing explosion protection in hazardous areas, the focus is often placed on electrical equipment such as motors, switches and junction boxes. While these components remain critical, ATEX fans must also be assessed for non-electrical ignition risks created by the mechanical operation of the fan itself.
The ExStream 300 & ExStream 400 ATEX fan is manufactured by Woodcock & Wilson for hazardous area ventilation applications where both electrical and mechanical ignition sources must be carefully controlled. In explosive atmospheres, ignition prevention extends beyond the motor terminal box and across the complete ventilation assembly.
Non-electrical ignition sources are recognised within international hazardous area standards including ISO 80079-36 and ISO 80079-37. These standards provide frameworks for identifying and assessing ignition hazards associated with mechanical equipment operating within explosive atmospheres.
Unlike electrical faults, mechanical ignition hazards can develop progressively over time through wear, contamination, vibration, misalignment or changing operating conditions.
Within ATEX fans, potential non-electrical ignition risks may include:
This is why hazardous area fan systems should always be assessed as complete mechanical and electrical assemblies rather than simply focusing on motor certification alone.
One of the most important distinctions in hazardous area engineering is the difference between regulatory compliance and genuine ignition prevention.
ATEX and IECEx certification schemes demonstrate that equipment meets recognised technical requirements. However, certification alone does not automatically eliminate every possible ignition source within a complete fan assembly.
Even with a certified motor, ignition risks may still arise from:
Safe hazardous area ventilation depends on understanding how the complete ATEX fan system behaves during both normal operation and foreseeable fault conditions.
Effective non-electrical ignition prevention relies on disciplined engineering practice throughout the equipment lifecycle.
Key considerations include:
Where ignition risks are controlled through operational limits or design features, these controls must remain effective throughout the equipment’s service life.
Thorne & Derrick distribute the following ATEX & IECEx hazardous area ventilation fans approved for explosive atmospheres:
Recent EU Safety Gate alerts have highlighted a serious issue for hazardous area operators: ATEX tablets and explosion-proof tablets being marketed as compliant without meeting the required intrinsic safety standards. Our range of ATEX Tablets from Pepperl+Fuchs has been developed for safe, reliable communication in hazardous areas where standard consumer devices are not suitable.
These alerts show a clear pattern. Some hazardous area tablets are being sold online or through industrial channels with claims of ATEX suitability for potentially explosive atmospheres, despite failing the design requirements needed for safe use in Zone-classified environments.
Our range of ATEX tablets has been developed for safe, reliable digital working in hazardous areas where standard consumer tablets are not suitable. Designed for use across oil & gas, chemical processing, petrochemical, pharmaceutical, energy, utilities and industrial manufacturing sectors, these rugged hazardous area tablets support inspection, maintenance, reporting, asset management and digital workflow applications.
Unsafe products marketed as ATEX tablets, intrinsically safe tablets or explosion-proof tablets can create serious ignition risks if they have not been properly designed, tested and certified to the required standards for explosive atmospheres.
This alert is an important reminder that not every device sold as an ATEX tablet can be trusted. For hazardous areas, industrial operators should only use genuine hazardous area tablets that have been properly designed, certified and supplied through trusted channels.
We supply genuine ATEX tablets for hazardous environments, helping industrial users work more safely while improving inspection efficiency, asset visibility, maintenance reporting and digital workflow access in Zone-classified areas.
Ideal for: oil & gas, chemical processing, petrochemical, pharmaceutical manufacturing, energy, utilities, process engineering, maintenance teams and other hazardous industrial sectors.
5G intrinsically safe smartphone with Android 15, global approvals, lone worker support and rugged field-ready design.
Rugged 5G hazardous area smartphone for Zone 2 applications with Android 15, Wi-Fi 6E and strong enterprise security credentials.
Future-ready 5G industrial smartphone with 6.3-inch display, 48 MP camera, eSIM support and optional scanning module for mobile workflows.
Explore the wider Pepperl+Fuchs hazardous area mobile computing portfolio, including additional ATEX phones, accessories, scanning solutions and related industrial communication devices.
A properly certified ATEX tablet is engineered for safe use in potentially explosive atmospheres, helping mobile workers access drawings, capture inspection records, manage permits, log maintenance data and communicate from the field without introducing unacceptable ignition risk.
Key concerns with fake or unsafe hazardous area tablets:
The lower cost of unsafe products can be a false economy. In hazardous areas, correct certification, trusted supply and proper product selection are essential. Industrial operators should always verify that any ATEX tablets used on site are genuine, correctly approved and suitable for the specific area classification.
Recent EU Safety Gate alerts have highlighted a growing issue across the industrial sector: mobile phones falsely marketed as ATEX or explosion-proof entering the supply chain.
There alerts involving hazardous area mobile phones demonstrate a clear pattern products are being marketed as compliant without meeting the required safety design standards.
Our range of ATEX Mobile Phones from Pepperl+Fuchs has been developed for safe, reliable communication in hazardous areas where standard consumer devices are not suitable. Covering Zone 1, Zone 2, Division 1, Division 2 and mining-certified applications, these rugged hazardous area smartphones support modern digital workflows across oil & gas, chemical, petrochemical, pharmaceutical, utilities, energy and industrial processing environments.
These devices are often sold online or through unverified suppliers, claiming suitability for Zone 1 or Zone 2 hazardous areas, but failing to meet the strict requirements of the ATEX Directive 2014/34/EU and intrinsic safety standards such as EN 60079-11.
This alert is a reminder that not every device marketed for hazardous areas can be trusted. For sites operating in explosive atmospheres, it is essential to use genuine ATEX mobile phones that have been properly designed, verified and supplied through trusted channels.
We supply genuine ATEX mobile phones for hazardous environments, helping industrial operators maintain safe communication, digital workflow access and compliance in Zone-classified areas.
Ideal for: oil & gas, chemical processing, petrochemical, pharmaceutical manufacturing, energy and other hazardous industrial sectors.
A concerning number of ATEX-certified products currently available do not meet essential safety standards. While some components within these products may carry individual certifications, the complete assemblies often lack proper testing and compliance.
Key Concerns:
Products marketed as ATEX-certified without meeting BS EN 14986:2017 requirements for mechanical safety
Incomplete compliance with ISO 80079-36 and -37 standards
Certificates that only validate electrical components, not full assemblies
Genuine risk of ignition when used in explosive atmospheres
The lower cost of non-compliant equipment represents a false economy, as these products may fail dangerously in hazardous environments. Responsible procurement requires thorough verification of all relevant certifications before purchase and use.
In industrial facilities, motors and machines are the backbone of production. Ensuring safe electrical connections and quick isolation during maintenance is critical for both operator safety and operational continuity.
Traditional hard-wired motor connections can make maintenance slower and increase downtime. Electrical connection systems designed for safe disconnection, visible isolation and lockout/tagout procedures help simplify servicing and reduce risk.
MARECHAL Electric provides industrial power connection solutions for motor supply applications up to 1,250A / 1,800kW, including plugs, sockets, decontactors and separable switch-disconnectors engineered for demanding industrial environments.
Electrical motor connections must do more than simply carry current. In modern industrial environments they must also help:
The MARECHAL Decontactor combines a plug, socket-outlet and built-in switching mechanism into a single device. This allows motors and equipment to be safely connected and disconnected under load up to 250A / 100kW without requiring an additional switch.
This design enables operators to isolate equipment quickly before maintenance or replacement, improving safety while simplifying servicing procedures.
Motor power connection equipment is often exposed to aggressive operating conditions including vibration, moisture, dust and mechanical shock. Reliable connection systems must therefore provide strong environmental protection.
For installations requiring visible and fully apparent breaking, the EVO40 separable switch-disconnector provides a reliable and compact isolation solution.
Designed from 2 to 6 poles, EVO40 allows load breaking and circuit interruption in accordance with IEC / EN 60947-3.
Because the connector can be separated and padlocked, maintenance teams can work safely while ensuring the circuit remains isolated.
Selecting the right motor connection system is not only about electrical capacity. It is also about improving safety and simplifying maintenance.
Published 13 Mar 2020
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