Can a soft starter panel be certified for ATEX or IECEx use in Zone 1 or Zone 2?

Yes, but the answer depends on the complete assembly and the protection concept used. A soft starter panel may be installed in Zone 1 or Zone 2 only if the enclosure, internal devices, cable entries, temperature rise, and marking all comply with the selected IEC 60079 protection method. In many projects, the panel is either placed outside the hazardous area or built into a certified pressurized enclosure under IEC 60079-2. If the design uses increased safety or intrinsic safety interfaces, those parts must meet the relevant clauses of IEC 60079-7 or IEC 60079-11. The final conformity also depends on the ATEX category and EPL required by the risk assessment.

What standards apply to a soft starter panel for hazardous areas?

The core standards are IEC 60079-0 for general requirements and the applicable protection-standard subset, such as IEC 60079-1, -2, -7, -11, or -31 depending on the hazard and protection concept. If the panel is a low-voltage assembly, IEC 61439-1 and IEC 61439-2 govern the assembly design, temperature rise, dielectric properties, and short-circuit withstand requirements. Installation practices are covered by IEC 60079-14, while inspection and maintenance are addressed in IEC 60079-17. For ATEX-marked equipment, the EU directives and corresponding harmonized standards apply, while IECEx follows the IEC certification framework with test reports and certificates recognized internationally.

How is temperature rise verified in an ATEX / IECEx soft starter panel?

Temperature rise verification is performed to prove that no component, conductor, or enclosure surface exceeds the permitted limits for the assigned T-class or dust temperature. The assessment typically combines calculation, manufacturer data, and type testing under worst-case loading, including maximum ambient temperature, full motor current, and enclosed heat dissipation from the soft starter, contactors, control power supplies, and any auxiliary devices. For assemblies under IEC 61439, temperature rise of busbars and terminals must be demonstrated, while IEC 60079 requires that external surfaces and internal components remain within the protection concept limits. If a VFD or other high-loss device is added, recalculation or retesting is usually necessary.

What documentation is required for ATEX / IECEx compliance?

A compliant package normally includes the technical file, risk assessment, design drawings, bill of materials, certificates for all relevant components, temperature-rise evidence, wiring diagrams, installation and maintenance instructions, and the final equipment marking. For ATEX, the manufacturer must keep a formal conformity assessment record and declare the applicable directive and category. For IECEx, the system typically needs an ExTR, quality assessment evidence, and an IECEx certificate or certificate of conformity depending on the scheme. If the panel includes certified glands, barriers, relays, or pressurization equipment, those certificates should be traceable in the dossier. Documentation control is critical because component substitution can invalidate the original compliance basis.

Can standard industrial components be used inside an Ex-rated soft starter panel?

Sometimes, but only if the chosen protection concept allows it and the components do not compromise compliance. For example, in a certified pressurized enclosure, many standard industrial devices may be used because the enclosure prevents explosive ingress, provided the pressurization system meets IEC 60079-2 and the internal temperature limits are respected. In other concepts, only certified Ex components, or devices with appropriate associated apparatus interfaces, may be permitted. Standard MCCBs, contactors, or soft starters cannot be assumed compliant merely because they are from a reputable brand such as Schneider Electric, ABB, Siemens, or Eaton; their suitability must be demonstrated in the context of the full assembly and installation conditions.

How do short-circuit ratings affect ATEX / IECEx panel design?

Short-circuit ratings are critical because a fault inside or upstream of the panel can create heat, arcing, and mechanical damage that defeats the hazardous-area protection concept. The assembly must be coordinated for the prospective fault current at the installation point, including the breaking capacity of the MCCB or ACB, the withstand strength of busbars, terminals, and contactors, and any conditional short-circuit current declared for the enclosure. Under IEC 61439, the panel builder must verify the short-circuit withstand capability by test, calculation, or design rules. In hazardous areas, this verification must be aligned with the Ex protection method so that a fault does not lead to ignition-capable surface temperatures or compromised enclosure integrity.

What testing is usually required before an Ex soft starter panel is released?

Typical verification includes visual inspection, wiring continuity, dielectric withstand testing where appropriate, functional checks, temperature-rise assessment, ingress protection validation, and review of Ex-specific installation details such as glands, blanking elements, earthing, and segregation. Depending on the design, additional assessment may include fault testing, pressurization leak testing, or review of intrinsic safety circuit parameters. The objective is to confirm that the final build matches the certified design and that any conditions of safe use are met. For repeat production, manufacturing quality checks and traceability records are also important. The release dossier should clearly show compliance with the relevant IEC 60079 and IEC 61439 requirements.

When does a soft starter panel need recertification after a design change?

Recertification or a formal engineering review is needed whenever a change can affect the explosion protection concept, electrical ratings, thermal behavior, or assembly integrity. Common triggers include replacing the soft starter model, changing the enclosure, modifying gland entries, adding a VFD or extra contactors, altering the cooling arrangement, increasing the motor current, or using a different protection relay. Even a component substitution that appears minor may affect temperature rise, creepage distances, or fault withstand performance. Under IECEx and ATEX frameworks, the manufacturer must ensure that the original technical basis remains valid; otherwise, a new assessment, updated test evidence, or revised certification may be required.

Panel + Standard

Soft Starter Panel — ATEX / IECEx Certification Compliance

ATEX / IECEx Certification compliance requirements, testing procedures, and design considerations for Soft Starter Panel assemblies.

Overview

Soft Starter Panel assemblies used in hazardous areas must be designed and documented to satisfy the applicable ATEX and IECEx conformity routes before they can be installed in explosive atmospheres. In practice, the panel builder must first determine the zone classification, gas group, temperature class, and equipment protection level required by the installation, then select a suitable protection concept for the enclosure and the internal electrical equipment. For many soft starter applications, the most important distinction is whether the complete assembly is mounted outside the hazardous area, installed in a pressurized or purged enclosure, or incorporated as part of an explosion-protected system with intrinsic safety interfaces, increased safety auxiliaries, or certified components only. Compliance is not just about the soft starter itself; it includes the enclosure, wiring system, terminals, barriers, segregation, surface temperature control, and the final technical file. For ATEX, the assembly must align with the applicable directives and harmonized standards, especially the EN/IEC 60079 series for explosive atmospheres. IECEx certification follows a similar technical basis but uses third-party test and assessment routes for international acceptance. Depending on the protection method, standards such as IEC 60079-0 for general requirements, IEC 60079-1 for flameproof equipment, IEC 60079-2 for pressurization, IEC 60079-7 for increased safety, IEC 60079-11 for intrinsic safety, and IEC 60079-14 for installation practices may apply. Where the panel is part of a low-voltage assembly, IEC 61439-1 and IEC 61439-2 govern switchgear and controlgear assemblies, while the hazardous-area aspects are verified separately. If the enclosure is intended for dust hazards, IEC 60079-31 becomes relevant. In combustible dust processing plants, the temperature rise of the soft starter, busbars, contactors, and control transformers must be checked against the maximum permissible surface temperature for the selected T-class or dust layer conditions. Typical components in a compliant Soft Starter Panel include a soft starter unit with suitable overload coordination, upstream MCCB or ACB protection, line and bypass contactors where required, motor protection relays, control power supplies, certified cable glands, breather drains if permitted, and certified terminal blocks or barriers for I/O. The choice of device ratings must reflect the short-circuit level at the installation point, with assembly verification covering prospective fault current, conditional short-circuit current, and protective coordination. For industrial duty panels, rated currents commonly range from 15 A up to 1000 A or more, depending on motor size and network conditions. If the assembly includes VFDs or other heat-producing devices alongside the soft starter, thermal management and component spacing become critical to maintain compliance and avoid hot spots. Verification for ATEX / IECEx typically includes design review, temperature rise assessment, electrical clearances and creepage checks, enclosure ingress protection validation, fault testing where applicable, and review of manufacturing controls and traceability. The technical documentation package must include the equipment category, EPL, marking, certificates, drawings, parts list, installation instructions, maintenance requirements, and any conditions of safe use. For repeat production, periodic inspection, modification control, and recertification after component substitution are essential. In real-world applications such as oil and gas skid packages, solvent handling plants, grain processing facilities, and chemical transfer stations, these requirements ensure that motor starting remains reliable without compromising ignition safety. Properly executed, ATEX / IECEx compliance transforms a standard Soft Starter Panel into a certifiable hazardous-area solution that can be accepted by EPC contractors, inspectors, and end users with confidence.

Key Features

ATEX / IECEx Certification compliance pathway for Soft Starter Panel
Design verification and testing requirements
Documentation and certification procedures
Component selection for standard compliance
Ongoing compliance maintenance and re-certification

Specifications

Panel Type	Soft Starter Panel
Standard	ATEX / IECEx Certification
Compliance	Design verified
Certification	Per applicable verification method

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Soft Starter Panel

ATEX / IECEx Certification

Frequently Asked Questions

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