Home > Sectors we serve > Explosion proof HVAC

Explosion proof HVAC

Hazardous areas contain flammable gases, vapours, dusts, or fibres at levels that present an ignition risk. HVAC systems influence how these atmospheres move, concentrate, and disperse, making their safe design critical.

Ex HVAC is highly customised to meet strict EPC specifications. Many systems are bespoke rather than off‑the‑shelf, requiring specialist engineering, appropriate Ex components, and validated design philosophies aligned with ATEX and IECEx.  Typical applications include:

  • Personnel cooling in hot climates (e.g., Middle East, offshore accommodation, floatels, drill ships)
  • Process cooling for refrigerants used in hydrogen, ammonia, and chemical operations
  • Pharmaceutical cleanrooms requiring contamination‑free, pressure‑controlled environment

 

Explosion proof HVAC

Ex instrumentation

Pyropress-Switch

Explosion proof switches

ATEX / IECEx / industrial.

Temperature, pressure, differential pressure, vacuum, fluid, flow and level conditions.

Pyropress Pressure Transmitter

Explosion proof transmitters

ATEX / IECEx / industrial.

Temperature, pressure, differential pressure, vacuum, fluid, flow and level conditions.

Technical example: Emergency Safety Shower Cooling

Standards EN 15154 and ANSI Z358.1 specify that emergency deluge water must remain tepid (typically 15–37°C). Pyropress® supplies hundreds of ultra reliable SIL2 explosion proof switches including flow, level and pressure switches to safety shower manufacturers for units that are used in hazardous areas in the middle east.  Explosion proof pressure switches activate the maximum cooling fan speed and provide a safety cut-off if the pressure is outside of the safe range. In addition, an explosion proof level switch for the condensate shuts off the system if, for example, the drain line becomes clogged or the pump fails. 

Technical example: Accommodation and Workplace Cooling

A typical hazardous area application has two pressure switches, one at low pressure at around 0.5 bar, a high pressure at around 30 bar, sitting in the appropriate places in the refrigeration cycle. There can be a third pressure switch set between these levels which is cycling the compressor, set with a larger differential or deadband. Some applications also have a Perseus level switch on the condensate tank, to switch on the pump to drain.

Technical example: Cleanrooms

Cleanrooms rely on stable positive pressurisation to prevent particulate ingress, supported by continuous differential‑pressure monitoring. Filtration is critical: HEPA/ULPA filters must be regularly checked and replaced, as blocked filters disrupt airflow and compromise pressurisation. Monitoring pressure drop across filters helps maintain efficiency and ensures the environment remains controlled, compliant, and contamination‑free.

Ex enclosures and components

Ex electrical enclosures are widely used for HVAC controls, particularity on refrigeration skids and process equipment. Ex p protection concepts are also often deployed to keep machinery such as large generator sets >1MW safe in hazardous areas. Ventilation strategies are required to keep the machinery cool while also maintaining above‑atmospheric pressurisation. Differential pressure switches and gas detectors, linked to Ex d enclosures, work together to ensure the Ex p system remains safely pressurised, continuously monitored, and properly ventilated.
Ex limit switches also ensure duct flaps and / or personal doors are at the correct status such as those offered by Ex-tech Solution, along with a range of other components used in explosion proof HVAC systems:

Control-Station

Control Stations

GRP, stainless steel or aluminium control stations that combine various functions. Customised solutions for many Ex applications.

Enclosure

Enclosures, control cabinets & junction boxes

A wide range of Ex d and Ex e enclosures in different materials including aluminium, GRP and stainless steel to suit different hazardous area applications. IIB and IIC gas groups are available.

Motor starters & isolators

The range includes rugged Ex d motor starters and switches that provide safety isolation during maintenance or repair of machines.

Selector Switch

Accessories, controls, switches & sensors

Compatible with PLC, ESD and DCS systems, these push buttons can also be used to activate alarms to alert personnel to potential dangers or many other functions.

Ex enclosure wiring<br />

Ex d enclosure & Ex e cabinet wiring service

To support the Ex-tech Solution product portfolio, the team also provides a specialised wiring service according to pre-approved customer designs.

Ex signalling

Many HVAC systems also incorporate audible and visual indication. The Ex-tech Signalling® SIL2 Ex beacons and sounders below help to indicate system status within hazardous areas.

Ex-tech Signalling Sounder

Explosion proof sounders

Powerful and clear audio alerts to ensure critical alerts are heard loud and clear in Zoned hazardous areas.

Ex-tech Signalling Beacon

Explosion proof beacons

Beacons and status lights designed for maximum visibility and reliability in hazardous areas.

Ex-tech Signalling Push Button

Explosion proof push buttons

Compatible with PLC, ESD and DCS systems, these push buttons can also be used to activate alarms to alert personnel to potential dangers or many other functions.

Hazardous area and Ex consultancy

Ex consultancy hazardous areas

For businesses handling flammable material

Hazardous area classification, DSEAR risk assessments, ignition hazard assessments, ATEX audits, training and more

explosion protection product development

For OEMs and suppliers of products

Help to expand portfolios into Ex applications, providing end to end Ex design, test and certification support.

White Paper: An Ex certified guide to HVAC

Download our free white paper for Ex HVAC system designers, specifiers, OEMs, users, and ATEX/ IECEx professionals worldwide, by Pioneer Safety Group (published April 2026).

You may also be interested in:

    Industry News & Insight