The Cygnus 1 Ex Ultrasonic Thickness Gauge stands out because it’s Intrinsically Safe and certified for use in Zone 0 hazardous areas – the most dangerous classification. But what do these certifications really mean? This article breaks down the terminology, regulations, and safety standards that make this device exceptional in its class.
Understanding Explosive Atmospheres
The term “Ex” refers to explosive atmospheres and is globally recognized in systems designed to prevent explosions.
Hazardous Areas are environments where flammable gases, vapours, or dust may be present in concentrations that can ignite. Equipment used in these areas must meet strict safety standards to prevent sparks or high surface temperatures that could cause explosions.
Global Ex Certification Schemes
Many countries adopt Ex certification schemes based on international standards, mainly those outlined by the IECEx system (International Electrotechnical Commission Explosive). IECEx provides a globally accepted framework to ensure equipment safety in explosive environments.
Here’s how some major certification systems align with IEC standards:
| Region | Scheme | Standard |
|---|
| Europe | ATEX | EN 60079 |
| North America | NEC/UL | UL 60079 |
| United Kingdom | UKEX | BS EN 60079 |
| Brazil | INMETRO | EN 60079 |
The Cygnus 1 Ex is certified to IECEx, ATEX, and UKEX, and is the only ultrasonic thickness gauge approved for ATEX Zone 0, the highest safety classification. This is equivalent to NEC (UL) Class I Division 1 Group “ALL” in North America.
Zones and Divisions Explained
Hazardous areas are categorized to define the level of risk:
European and IECEx Zone Classification
- Zone 0: Explosive atmosphere present continuously or for long periods.
- Zone 1: Likely to occur in normal operation.
- Zone 2: Unlikely in normal operation, or only for a short time.
North American Division Classification
- Division 1 = Zone 0 or Zone 1
- Division 2 = Zone 2.
The most hazardous environment is Zone 0 / Division 1, where explosive gases are nearly always present. These areas require the highest level of protection, which the Cygnus 1 Ex is built to meet.
Why Ex Certification is Superior to Other Testing Methods
You may come across other testing standards, such as MIL-STD-810G, but these do not offer the same level of assurance.
| Feature | Ex Certification
(IECEx / ATEX / UKEX) | MIL-STD-810G |
|---|
| Safety by design | ✅ | ❌ |
| Independent certification body | ✅ | ❌ |
| Ongoing manufacturer audits | ✅ | ❌ |
| Multiple fault conditions tested | ✅ | ❌ |
| Battery safety under fault | ✅ | ❌ |
| Battery safety under fault | ✅ | ❌ |
| Drop-tested and anti-static materials | ✅ | ❌ |
| Legal approval for use in Ex zones | ✅ | ❌ |
MIL-STD-810G merely tests whether a device will cause an explosion during a single test under very specific conditions. It doesn’t consider real-world scenarios like equipment faults, battery issues, or long-term durability. In contrast, Ex certification requires the device to be safe even if something goes wrong.
Final Thoughts
The Cygnus 1 Ex isn’t just another ultrasonic gauge – it’s built from the ground up to perform safely in the most hazardous environments on Earth. Designed and manufactured in the UK, it comes with a 3-year warranty and is fully compliant with the world’s most rigorous Ex standards.
Stay tuned for our next article, where we’ll explain:
- What “Intrinsically Safe” really means
- The role of Equipment Protection Levels (EPLs)
- When Hot Work Permits are needed.
Cygnus 1 Ex – trusted, tested, and ready for the world’s toughest environments.
*Limited-Time Offer: Ends 31 December 2025.
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