Installing a Flameproof Split Air Conditioner in hazardous industrial environments is very different from standard domestic installation. Zone-rated equipment requires strict compliance with IS/IEC 60079 standards, and poor installation can invalidate certification and introduce ignition risks.
This guide covers correct installation practices for Refrigerant Piping, Copper Tube Routing, Electrical Glanding, Drain Lines, Local Isolation, Commissioning, and PESO inspection requirements.
For background on hazardous area classification, refer to: A Comprehensive Guide to Zone 0, Zone 1, Zone 2, and Zone 3 → https://www.flameproof.co.in/a-comprehensive-guide-to-zone-0-zone-1-zone-2-and-zone-3-in-hazardous-areas/
A Flameproof Split AC installed in a Zone 1 hazardous area must include: a certified Ex d/Ex e indoor unit, sealed copper pipe routing through mechanically protected trays and gas-tight wall penetration, armored cables with Ex d double compression glands, a local flameproof isolator switch, nitrogen pressure testing, and a U-trap sealed drain. Incorrect sealing or exposed soft copper immediately voids PESO compliance.
Explore certified systems: Flameproof Split Air Conditioner → https://www.flameproof.co.in/product/flameproof-split-air-conditioner/
Component | Typical Location | Certification Requirement |
Indoor Unit | Zone 1 / Zone 2 | Ex d / Ex e |
Outdoor Unit | Safe Area preferred | If Zone 1/2 → Ex d compressor |
Refrigerant Piping | Interconnecting corridor | Protected in metal tray |
Power & Control Cable | GI tray / rigid conduit | Armored + Ex d glands |
Drain Line | Independent routed | U-trap vapour barrier |
Important Engineering Note:
If a nearby Safe Area is available, mount the outdoor unit there to reduce cost and simplify certification. If not, certified Ex d outdoor units must be used.
Modern HVAC uses:
A sealed Ex d compressor housing ensures refrigerant cannot leak into the explosive atmosphere during component failures.
Requirement | Correct Practice |
Power Cable | Armored cable, no FRLS twin core |
Cable Glands | Ex d double compression only |
Junction Box | Certified Flameproof JB only |
Earthing | Dedicated body + safety earth |
Segregation | Cable trays separate from drain lines |
Drain lines are often overlooked but can become a direct vapour path from outside to Zone 1.
Requirement | Rule |
Slope | Minimum 1:100 |
Trap | U-trap mandatory |
Seal | Continuous water barrier |
Routing | Avoid cable tray proximity |
Step | Requirement |
Filling Pressure | 350–450 PSI nitrogen |
Hold Duration | 24 hours |
Permissible Drop | <10 PSI |
Vacuum Level | 500 microns |
Leak Checking | Soap-water / UV dye |
