AS/NZS 3800:2005

1 - AS/NZS 3800:2005 ELECTRICAL EQUIPMENT FOR EXPLOSIVE ATMOSPHERES-REPAIR AND OVERHAUL
4 - PREFACE
6 - CONTENTS
9 - FOREWORD
10 - SECTION 1 SCOPE AND GENERAL
10 - 1.1 SCOPE
10 - 1.2 APPLICATION
11 - 1.3 REFERENCED DOCUMENTS
12 - 1.4 DEFINITIONS
12 - 1.4.1 Approved
12 - 1.4.2 Australian Qualification Framework (AQF)
12 - 1.4.3 Certification
12 - 1.4.4 Competent person
12 - 1.4.5 Encapsulation (Ex ‚m™)
13 - 1.4.6 Enclosure, dust-excluding ignition-proof (DIP enclosure)
13 - 1.4.7 Equipment
13 - 1.4.8 Explosion-protection
13 - 1.4.9 Explosive gas atmosphere
13 - 1.4.10 Ex Testing Laboratory (ExTL)
13 - 1.4.11 Flameproof enclosure (Ex ‚d™)
13 - 1.4.12 Flameproof joint
14 - 1.4.13 Gap (diametral clearance)
14 - 1.4.14 Hazardous area
14 - 1.4.15 Increased safety protection (Ex ‚e™)
14 - 1.4.16 Intrinsically safe electrical equipment (Ex ‚i™)
14 - 1.4.17 Length of flamepath (width of joint)
14 - 1.4.18 Maintenance
14 - 1.4.19 Maximum surface temperature
14 - 1.4.20 Modification
15 - 1.4.21 Non-sparking protection (Ex ‚n™)
15 - 1.4.22 Operating rod (spindle)
15 - 1.4.23 Overhaul
15 - 1.4.24 Overhaul and examination report
15 - 1.4.25 Pressure piling
15 - 1.4.26 Pressurization (Ex ‚p™)
15 - 1.4.27 Recognized service facility
15 - 1.4.28 Repair
15 - 1.4.29 Replacement
15 - 1.4.30 Sand-filled enclosure (Ex ‚q™)
15 - 1.4.31 Special protection (Ex ‚s™)
16 - 1.4.32 Temperature classification
16 - 1.4.33 Verification dossier
16 - 1.5 DOCUMENTATION/INFORMATION
16 - 1.5.1 General
16 - 1.5.2 Where certification documentation is not available but sufficient information is available to identify the type of...
17 - 1.5.3 Insufficient information
17 - 1.5.4 Traceability/marking
17 - 1.5.5 Variation from certification documents
18 - 1.5.6 Acceptance criteria
18 - 1.6 MIXED EXPLOSION-PROTECTION TECHNIQUES
18 - 1.7 GROUPING OF EXPLOSION-PROTECTED ELECTRICAL EQUIPMENT
18 - 1.7.1 Group designation
18 - 1.7.2 Group II subdivision
18 - 1.8 ROLE OF COMPETENT PERSONS
19 - SECTION 2 FLAMEPROOF ENCLOSURES (Ex 'd')
19 - 2.1 GENERAL
19 - 2.1.1 Flameproof enclosures
19 - 2.1.2 Use of greases
19 - 2.1.3 Fixing bolts, studs and nuts
19 - 2.1.4 Attachments
19 - 2.1.5 Replacement
19 - 2.1.6 Machining
19 - 2.1.7 Joint surfaces
19 - 2.1.8 Mixed protection techniques
19 - 2.2 CERTIFICATION
19 - 2.2.1 General
20 - 2.2.2 Flameproof tests
20 - 2.3 CATEGORIES OF WORK
20 - 2.3.1 General
20 - 2.3.2 Overhaul-No repair
20 - 2.3.3 Overhaul-Repair
20 - 2.3.4 Modifications
22 - 2.4 OVER-PRESSURE TESTING
22 - 2.4.1 General
23 - 2.4.2 Water-cooled motors and enclosures
23 - 2.4.3 Enclosures with screwed covers
23 - 2.5 OVERHAUL AND REPAIR PROCEDURES
23 - 2.5.1 Overhaul of Ex ‚d™-Flameproof motors
24 - 2.5.2 Overhaul of Ex™d™-Flameproof enclosures
26 - 2.5.3 Overhaul of electrical equipment installed within Ex ‚d™ enclosures
29 - SECTION 3 INTRINSIC SAFETY(Ex 'i')
29 - 3.1 GENERAL
29 - 3.2 EQUIPMENT
29 - 3.2.1 Enclosures
29 - 3.2.2 Ingress protection
29 - 3.2.3 Plugs and sockets
29 - 3.2.4 Terminations
30 - 3.2.5 Fuses
30 - 3.2.6 Printed circuit boards
30 - 3.2.7 Optocouplers
30 - 3.2.8 Piezo-electric devices
30 - 3.2.9 Multi-core cables
30 - 3.2.10 Fibre optic cable
30 - 3.2.11 Electrical parts
30 - 3.2.12 Batteries
30 - 3.2.13 Transformers
31 - 3.2.14 Encapsulated parts
31 - 3.2.15 Non-electrical parts
31 - 3.3 MODIFICATIONS
31 - 3.4 OVERHAUL AND REPAIR PROCEDURES
31 - 3.4.1 General procedures
32 - 3.4.2 Specific procedures
34 - SECTION 4 INCREASED SAFETY (Ex 'e')
34 - 4.1 GENERAL
34 - 4.2 EQUIPMENT
34 - 4.2.1 Enclosures
34 - 4.2.2 Ingress protection
34 - 4.2.3 Plugs and sockets
34 - 4.2.4 Terminations
35 - 4.2.5 Internal connections
35 - 4.2.6 Electrical parts
35 - 4.2.7 Batteries
35 - 4.2.8 Transformers
35 - 4.2.9 Light transmitting parts
35 - 4.2.10 Lamps
35 - 4.2.11 Lampholders
35 - 4.2.12 Ballasts and capacitors
35 - 4.2.13 Encapsulated parts
35 - 4.2.14 Insulation
36 - 4.2.15 Winding connections
36 - 4.3 MODIFICATIONS
36 - 4.3.1 Modifications permitted by certification
36 - 4.3.2 Modifications not permitted within certification
36 - 4.4 CERTIFICATION
36 - 4.5 OVERHAUL AND REPAIR PROCEDURES
36 - 4.5.1 Motor windings
38 - 4.5.2 Overhaul of Ex ‚e™-Increased safety motors
39 - 4.5.3 Overhaul of Ex ‚e™-Increased safety enclosures
40 - 4.5.4 Overhaul of electrical equipment installed within Ex ‚e™ enclosures
42 - SECTION 5 PRESSURIZED ENCLOSURES (Ex ‚p™)
42 - 5.1 GENERAL
42 - 5.2 PRESSURIZATION
42 - 5.3 ENCLOSURES
42 - 5.3.1 Materials
42 - 5.3.2 Joints in the enclosure
42 - 5.3.3 Gaskets and seals
42 - 5.3.4 Fasteners
43 - 5.3.5 Cable entries
43 - 5.4 TEMPERATURE RATING
43 - 5.4.1 Lighting fittings
43 - 5.4.2 Heat-generating equipment
43 - 5.5 OVERHAUL AND REPAIR PROCEDURES
45 - SECTION 6 NON-SPARKING (Ex 'n')
45 - 6.1 GENERAL
45 - 6.2 EQUIPMENT
45 - 6.2.1 Enclosures
45 - 6.2.2 Ingress protection
45 - 6.2.3 Plugs and sockets
46 - 6.2.4 Terminations
46 - 6.2.5 Internal connections
46 - 6.2.6 Electrical parts
46 - 6.2.7 Batteries
46 - 6.2.8 Transformers
46 - 6.2.9 Light-transmitting parts
46 - 6.2.10 Lamps
46 - 6.2.11 Lampholders
46 - 6.2.12 Ballasts and capacitors
47 - 6.2.13 Encapsulated parts
47 - 6.2.14 Insulation
47 - 6.2.15 Winding connections
47 - 6.3 MODIFICATIONS
47 - 6.3.1 Modifications permitted by certification
47 - 6.3.2 Modifications not permitted within certification
47 - 6.4 CERTIFICATION
48 - 6.5 OVERHAUL AND REPAIR PROCEDURES
48 - 6.5.1 Motor windings
49 - 6.5.2 Overhaul of Ex ‚n™-Non-sparking motors
50 - 6.5.3 Overhaul of Ex ‚n™-Non-sparking enclosures
51 - 6.5.4 Overhaul of electrical equipment installed within Ex ‚n™ non-sparking enclosures
53 - SECTION 7 ENCAPSULATION (Ex 'm')
53 - 7.1 PRINCIPLES OF ENCAPSULATION (Ex ‚m™)
53 - 7.2 APPLICATION
53 - 7.3 REPAIR AND OVERHAUL
53 - 7.3.1 Associated protection techniques
53 - 7.3.2 Removal of encapsulation material
54 - 7.3.3 Replacement of components
54 - 7.3.4 Preparation for replacing encapsulation
54 - 7.3.5 Encapsulating material
54 - 7.3.6 Pouring encapsulation material
55 - 7.3.7 Visual inspection
55 - 7.4 RECLAMATION
55 - 7.5 MODIFICATIONS
56 - SECTION 8 DUST EXCLUDING IGNITION-PROOF (DIP)
56 - 8.1 GENERAL
56 - 8.2 EQUIPMENT
56 - 8.2.1 Enclosures
56 - 8.2.2 Cable and conduit entries
56 - 8.2.3 Incomplete documentation/information
57 - 8.3 AUXILIARY EQUIPMENT
57 - 8.3.1 Dust-excluding brake units
57 - 8.3.2 Auxiliary devices
57 - 8.3.3 Light-transmitting parts
57 - 8.3.4 Encapsulated parts
57 - 8.3.5 Batteries
57 - 8.3.6 Lamps
57 - 8.3.7 Lampholders
57 - 8.3.8 Ballasts
57 - 8.3.9 Interlocks
57 - 8.4 MECHANICAL REPAIRS
57 - 8.4.1 Damage to components
57 - 8.4.2 Joints
58 - 8.4.3 Spigoted joints
58 - 8.4.4 Shafts and housings
58 - 8.4.5 Boots
58 - 8.4.6 Journals
58 - 8.4.7 Damaged stator cores
58 - 8.5 MODIFICATIONS
58 - 8.6 CERTIFICATION
58 - 8.7 OVERHAUL AND REPAIR PROCEDURES
58 - 8.7.1 Motor windings
59 - 8.7.2 Overhaul of DIP motors
60 - 8.7.3 Overhaul of DIP enclosures
60 - 8.7.4 Overhaul of DIP electrical equipment installed within DIP enclosures
62 - SECTION 9 USER INFORMATION
62 - 9.1 SCOPE
62 - 9.2 GENERAL REPAIR/OVERHAUL INFORMATION
62 - 9.2.1 General
62 - 9.2.2 Certification
62 - 9.2.3 Overhaul and examination reports
62 - 9.2.4 Overhaul frequency
62 - 9.3 SPECIFIC INFORMATION
62 - 9.3.1 General
62 - 9.3.2 Flameproof
63 - 9.4 DECIDING ON REPAIR OR REPLACEMENT
64 - APPENDIX A - REQUIREMENTS FOR REPAIR AND OVERHAUL SERVICE FACILITIES
64 - A1 SCOPE
64 - A2 REQUIREMENTS FOR SERVICE FACILITIES
64 - A2.1 Type of service facility
64 - A2.2 Personnel
64 - A2.3 Facilities
66 - APPENDIX B - PRINCIPLES OF FLAMEPROOF ENCLOSURES (Ex ‚d™)
66 - B1 INTRODUCTION
66 - B2 CHARACTERISTICS OF FLAMEPROOF ENCLOSURES
67 - B3 OVERHAUL OF FLAMEPROOF ENCLOSURES
67 - B3.1 General
67 - B3.2 Flameproof motors
67 - B3.3 Maximum surface temperature
67 - B3.4 Fixing bolts, studs and nuts
68 - B3.5 Breathing devices
69 - APPENDIX C - PRINCIPLES OF INCREASED SAFETY (Ex ‚e™)
69 - C1 INTRODUCTION
69 - C2 ARCING OR SPARKING PARTS
69 - C3 INSULATION
69 - C4 TEMPERATURE
70 - C5 TERMINALS AND TERMINATIONS
71 - APPENDIX D - IDENTIFICATION OF REPAIRED EQUIPMENT
71 - D1 TRACEABILITY
71 - D1.1 General
71 - D1.2 Minimum marking
71 - D1.3 Form of marking
71 - D1.4 Subsequent overhauls
73 - APPENDIX E - TESTS OF JOINT SURFACES USING STRAIGHTEDGES
74 - APPENDIX F - CORROSION OR SURFACE INDENTATION TOLERANCES
76 - APPENDIX G - OVER-PRESSURE TEST
76 - G1 INTRODUCTION
76 - G2 TEST PROCEDURE
77 - G3 REPORTING OF RESULTS
77 - G4 INTERPRETATION OF RESULTS
79 - APPENDIX H - EXAMPLES OF OVER-PRESSURE TEST RIGS
80 - APPENDIX I - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR FLAMEPROOF MOTORS (Ex ‚d™)
82 - APPENDIX J - CHECK OF CIRCULAR FLANGES, SPIGOTS AND HOLES
82 - J1 SCOPE
84 - APPENDIX K - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR FLAMEPROOF ENCLOSURE (Ex ‚d™)
85 - APPENDIX L - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR ELECTRICAL EQUIPMENT INSTALLED WITHIN FLAMEPROOF...
87 - APPENDIX M - PRINCIPLES OF INTRINSIC SAFETY (Ex ‚i™)
87 - M1 INTRODUCTION
87 - M2 CHARACTERISTICS OF INTRINSIC SAFETY
87 - M2.1 General
88 - M2.2 Groups
88 - M2.3 Categories
88 - M2.4 Intrinsically safe electrical equipment and systems
88 - M2.5 Safety barriers
89 - M2.6 Testing/assessment
90 - M3 OVERHAUL OF INTRINSIC SAFETY EQUIPMENT
92 - APPENDIX N - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR INTRINSICALLY SAFE EQUIPMENT (Ex ‚i™)
93 - APPENDIX O - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR INCREASED SAFETY MOTORS (Ex ‚e™)
95 - APPENDIX P - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR INCREASED SAFETY ENCLOSURES (Ex ‚e™)
96 - APPENDIX Q - TYPICAL OVERHAUL AND EXAMINATION REPORT FOR ELECTRICAL EQUIPMENT INSTALLED WITHIN INCREASED SAFETY ENCLOSURES
97 - APPENDIX R - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR PRESSURIZED ENCLOSURES INCLUDING PRESSURIZED...
98 - APPENDIX S - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR NON-SPARKING MOTORS (Ex ‚n™)
100 - APPENDIX T - A TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR NON-SPARKING ENCLOSURES (Ex ‚n™)
101 - APPENDIX U - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR ELECTRICAL EQUIPMENT INSTALLED WITHIN NON-SPARKING...
102 - APPENDIX V - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR ENCAPSULATED EQUIPMENT (Ex ‚m™)
103 - APPENDIX W - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR DIP MOTORS
105 - APPENDIX X - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR DIP ENCLOSURES
106 - APPENDIX Y - TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR ELECTRICAL EQUIPMENT INSTALLED WITHIN DIP ENCLOSURES
107 - APPENDIX Z - GUIDANCE FOR MEASUREMENTS IN FLAMEPROOF EQUIPMENT, WHEN REPAIRED/OVERHAULED
107 - Z1 GENERAL
107 - Z2 GUIDANCE FOR TOLERANCES
107 - Z2.1 Shafts with rolling-element bearings
108 - Z2.2 Flanged joints

Sets out requirements for repair and overhaul of electrical equipment used in hazardous areas, which are defined in AS/NZS 60079.10 for gases and AS/NZS 61241.10 for dusts. It covers equipment having a group designation of Group I for coal mining and Group II for all other industries where flammable gases and vapours may be present. It covers all types of explosion-protection techniques and specifies requirements for repair and overhaul service facilities.

This Standard sets out requirements for the repair and overhaul of electrical equipment used in hazardous areas; these hazardous areas are defined in AS/NZS60079.10 for gases and in AS/NZS61241.10 for dusts. The Standard covers equipment having a group designation of GroupI for coal mining and GroupII for all other industries where flammable gases and vapours may be present. It also includes equipment used in the presence of combustible dusts. This Standard does not cover maintenance of explosion-protected electrical equipment; however where maintenance affects the explosion-protection properties of the equipment, the requirements of this Standard for assessment, procedure and recording of data shall be met. This Standard details the methods of overhaul, examination and the testing required to ensure safety and compliance with the relevant equipment Standards for the different types of explosion-protection. It covers the several types of explosion-protection techniques currently in use and specifies requirements for repair and overhaul service facilities.This Standard also deals with modifications where they form part of an overhaul or repair process.In all cases, the basic requirement for repair and overhaul is that such work comply with the relevant Standard for each type of explosion-protection. These Standards may be supplemented by specific requirements issued by a regulatory authority. Users of this Standard should check on the current status of such regulations and the conditions applying within the certification documents.Guidelines are also laid down for practices to be adopted by the recognized service facility to carry out work effectively, to the satisfaction of both the user and the regulatory authorities.Attention is drawn to the various occupational health and safety Acts, and regulations under these Acts.The requirements may vary between the various Australian States as well as New Zealand but are nonetheless binding on equipment suppliers and users.

Originated in Australia as AS 2290.2-1979.
Final Australian edition AS 2290.2-1993.
Originated in New Zealand as NZS 6112:1989.
AS 2290.2-1993 and NZS 6112:1989 jointly revised, amalgamated and designated AS/NZS 3800:1997.
Second edition 2005.