ATEX & hazardous areas
DESIGNING FOR ZONE 2 AND ZONE 22 For Zone 2 and Zone 22 environments, the objective is not to contain an explosion in the way that is required in more high-risk areas, but to reduce the likelihood of ignition under abnormal conditions. That distinction allows for a very different design philosophy. Kollmorgen’s AKME series of servo motors was developed specifically for these applications. Rather than redesigning the motor as a flameproof enclosure, the approach builds on the established AKM servo platform and applies targeted enhancements to meet the requirements for Zone 2 and Zone 22. The design makes use of several key protection concepts. For gas environments in Zone 2, the motor employs increased safety and encapsulation. The windings are vacuum impregnated to isolate conductive components and reduce the risk of ignition sources, while the design meets the T4 temperature class requirement. In practice, gases may enter the motor, but the rotor surface temperature remains well below the ignition threshold. For dust environments in Zone 22, protection is achieved through a sealed enclosure. The motors incorporate IP67- rated shaft sealing and connector sealing, exceeding the IP64 level required by the certification standard. This ensures that dust cannot accumulate inside the motor and allows it to meet the T130 temperature classification for dust that may settle on the motor surface.
Because the motor is not required to withstand an internal explosion, it does not need thick-walled housings or flame paths. The result is a compact, lightweight solution that preserves the torque density, dynamic performance and mounting flexibility expected of a modern servo motor.
A MEASURED APPROACH TO SAFETY It is important to note that adopting a more measured response to motor specification does not diminish the importance of safety. On the contrary, increasing awareness of combustible dust and gas hazards have improved industry standards significantly. The goal is not to reduce protection, but to apply it intelligently. Hazardous location classification exists precisely to enable proportionate design. When engineers understand the nature, frequency and duration of the hazard, they can select equipment that provides the required level of protection without introducing unnecessary compromise. As automation continues to expand into food production, pharmaceutical processing, advanced coatings and other dust- and gas-sensitive environments, this middle ground between standard industrial servo motors and fully explosion-proof designs will become more important. The challenge for designers is to resist the instinct to default to the highest rating and instead align specifications with real-world risk. By doing so, they can achieve compliant, efficient, and mechanically optimised systems that reflect both engineering rigor and practical judgment. In modern factory automation, safety and performance are not opposing goals. Indeed, with the right approach to hazardous location specification, they instead reinforce each other.
Kollmorgen
www.kollmorgen.com Instrumentation Monthly June 2026 31
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