Explosion-Proof and Intrinsically Safe ISO 5599-1 Valves by Automatic Valve

Certifications and Hazardous Area Classifications

Automatic Valve hazardous location ISO 5599-1 valves carry a comprehensive set of internationally recognized certifications. FM Approved explosion-proof models are rated for Class I, Division 1, Groups A, B, C, and D with T4 temperature classification at Ta equal to 60 degrees C. Additional FM ratings include encapsulation/explosion-proof for Class I Zone 1, dust-ignition proof for Class II and III Division 1 Groups E, F, and G, non-incendive for Class I Division 2, and suitability for Class II and III Division 2 hazardous locations.

CSA Approved models cover Class I Division 1 Groups A through D, Class II Groups E, F, and G, and Class III environments. ATEX Approved models carry the designation II 2 G Ex mb IIC T5 and II 2 G Ex mb tb IIIC T95 degrees C for European zone-classified installations. These comprehensive certifications ensure that Automatic Valve ISO 5599-1 hazardous location valves can be deployed in virtually any classified environment worldwide.

Intrinsically safe versions are rated IS Class I, II, and III Division 1, Groups A through G, with T5 temperature class and ambient range of -40 degrees C to 50 degrees C. The intrinsically safe circuit requires a Factory Mutual Entity Approved or CSA rated safety barrier, which must be sourced separately. The IP65 NEMA 7 enclosure rating provides robust environmental protection for all coil types.

Valve Features and Protection Methods

Hazardous location ISO 5599-1 valves incorporate the proven engineering features that define the Automatic Valve product line alongside specialized hazardous area protection. The compact, balanced spool construction delivers high performance in a low-profile package. The solenoid pilot uses full air line pressure to shift the valve, with solenoids guaranteed against burnout. A turn-locking manual override enables manual valve operation during electrical failure or commissioning.

Explosion-proof coils are designed to contain any spark originating from within the coil or housing, preventing the ignition of flammable material in the surrounding environment. These coils are available with both FM/CSA and ATEX certification options. Intrinsically safe coils limit the amount of electrical energy available in the circuit to below ignition thresholds, providing an alternative protection philosophy for environments where reduced energy levels are preferred.

The external pilot supply is easily field-convertible and makes these valves suitable for vacuum service applications in hazardous environments. The bidirectional tapered Tee-Seal has been tested tough and proven reliable according to SAE specifications with rust and water injection every 864,000 cycles through a 20-million-cycle life test. Internal or external pilot supply is available for all configurations.

Technical Specifications and Operating Parameters

Hazardous location ISO 5599-1 valves are engineered for reliable operation across standard and high temperature ranges. Standard temperature models operate from 0 degrees F to 123 degrees F (-18 degrees C to 50 degrees C), while high temperature models extend to 0 degrees F to 180 degrees F (-18 degrees C to 82 degrees C). For low temperature environments, models rated to -40 degrees F are available. Air must be free of water vapor below 40 degrees F.

Operating pressure varies by ISO size. Size 1 and Size 2 5/2 valves operate from 20 to 150 psig (1.4 to 10.3 bar), while Size 3 5/2 valves require 30 to 150 psig (2.1 to 10.3 bar). The 5/3 valve configurations require slightly higher minimum pressures depending on size and center position type. External pilot supply ranges from 35 to 150 psig for most configurations.

Explosion-proof solenoids are available in DC (12V and 24V) and AC (120V and 240V at 60 Hz) options with 4.5-watt DC power consumption. Intrinsically safe solenoids operate on 24V DC at 1.6 watts with 0.05 Amp holding current. Explosion-proof electrical connections include 1/2-inch conduit coils with leads for FM/CSA models and strain relief with cord for ATEX models. Manifold connections are available in NPT and G thread configurations.

Sub-Bases, Manifolds, and Mounting Systems

The ISO 5599-1 standardized mounting interface ensures full interchangeability of hazardous location valves with any sub-base or manifold system manufactured to the same specification. Individual sub-bases provide standalone mounting for single valve applications with threaded port connections sized to each ISO valve size. Sub-base port thread options include NPT and G configurations.

Manifold bases enable multi-valve assemblies that reduce piping complexity, minimize leak points, and streamline installation in hazardous environments. Manifold systems can be configured with end stations providing centralized supply and exhaust connections. Manifold accessories include blanking plates for unused stations, intermediate supply plates, and connection adapters that allow flexible system configuration.

The standards-based approach of ISO 5599-1 mounting is particularly valuable in hazardous location applications where equipment replacement and maintenance must be performed efficiently to minimize exposure time in classified areas. The interchangeable base interface allows valve replacement without disturbing the piping infrastructure, reducing downtime and maintaining system integrity.

Applications and Industry Use Cases

Automatic Valve hazardous location ISO 5599-1 valves serve industries where pneumatic automation operates in explosive atmospheres. Petrochemical refineries use these valves for actuator control on process valves in classified areas. Oil and gas production facilities deploy them on wellhead and pipeline equipment. Chemical processing plants rely on their certified protection for reactor control, material handling, and packaging operations.

Pharmaceutical manufacturing, grain handling and storage, mining operations, paint and coating application, and fuel handling facilities all present environments where flammable gases, combustible dust, or ignitable fibers demand explosion-proof or intrinsically safe protection. The ISO 5599-1 standardized interface ensures that these valves integrate seamlessly into existing control system architectures.

Engineers can select from explosion-proof FM/CSA, explosion-proof ATEX, or intrinsically safe coil types based on the specific hazardous area classification, regional certification requirements, and system design philosophy. Downloadable CAD models support efficient plant design, and Automatic Valve's global support network through the ROSS Global Family provides engineering assistance and aftermarket support from the Ferndale, Michigan headquarters and offices across the Americas, Europe, and Asia-Pacific.

Frequently Asked Questions About Hazardous Location ISO 5599-1 Valves

What hazardous area classifications do ISO 5599-1 explosion-proof valves cover?

Automatic Valve hazardous location ISO 5599-1 valves are certified for Class I Division 1 Groups A through D (flammable gases and vapors), Class II Division 1 Groups E, F, and G (combustible dust), and Class III (ignitable fibers). FM, CSA, and ATEX certifications are available. Division 2 and Zone 1 ratings are also included for broader installation flexibility.

Are hazardous location ISO 5599-1 valves interchangeable with standard ISO 5599-1 valves?

Yes, the hazardous location ISO 5599-1 valves conform to the same ISO 5599-1 mounting interface dimensional standard as standard valves. They mount on the same sub-bases and manifold systems, allowing easy upgrades from standard to hazardous location valves without changing the base infrastructure.

What sizes are available for hazardous location ISO 5599-1 valves?

Automatic Valve offers hazardous location ISO 5599-1 valves in all three standard ISO sizes. Size 1 provides Cv 1.0 (980 Nl/min), Size 2 delivers Cv 2.0 (2,000 Nl/min), and Size 3 offers Cv 4.0 (3,900 Nl/min). Manifold inlet port sizes range from 1/8 inch to 3/4 inch.

What SIL rating do hazardous location ISO 5599-1 valves achieve?

Hazardous location ISO 5599-1 valves are certified by SGS-TUV Saar per IEC 61508 and achieve Safety Integrity Level 2 (SIL 2) rating. This certification supports integration into safety instrumented systems in classified environments.

Can both explosion-proof and intrinsically safe ISO 5599-1 valves be manifold mounted?

Yes, both explosion-proof and intrinsically safe versions of ISO 5599-1 valves can be mounted on standard ISO 5599-1 manifold bases and sub-bases. Manifold mounting reduces piping complexity and simplifies installation in hazardous environments. Manifold accessories include end stations, blanking plates,