Last Updated: April 21, 2026

Explosion-Proof Collaborative Robots: ATEX / IECEx Certified XR Series Configuration Guide

An explosion-proof collaborative robot is a cobot engineered for deployment in atmospheres where gas, vapour, or combustible dust can ignite, and where a standard robot would create an unacceptable ignition risk. ATEX and IECEx are the two primary certification frameworks that verify a robot is safe for these environments. EVST is the first Chinese cobot manufacturer to hold both ATEX (Directive 2014/34/EU) and IECEx dual certification on a production cobot line, with an IP68 ingress rating across the full XR-Ex series.

For broader industry context on collaborative robots, see the Explosion-Proof Cobots for Hazardous Environments: Complete Industry Guide on evsint.com.

Why Explosion-Proof Cobots Exist

Standard cobots generate ignition sources. Electrical arcing at connectors, static discharge from polymer housings, brush motors, and even capacitor discharge during e-stop events can all ignite a flammable atmosphere. In chemical plants, oil refineries, pharmaceutical solvent processing areas, battery electrolyte filling lines, and munitions assembly, the consequence of a single ignition event is not a minor safety incident. It is an explosion that can destroy equipment and kill personnel.

Automation in these settings is not optional. Manual labour in a Zone 1 classified area carrying an ignitable liquid sample or a tray of energetic material is itself a risk. Repetitive, high-precision tasks (sample extraction, liquid dispensing, component placement) are exactly what a cobot handles well. The engineering challenge is building a cobot that performs those tasks without becoming the ignition source.

The industries that require explosion-proof cobots share a common characteristic: the hazardous atmosphere is either continuous (Zone 0 / Zone 20) or intermittently present during normal operation (Zone 1 / Zone 21). In oil and gas wellheads, flammable gas is always present. In a pharmaceutical tablet-coating line using ethanol solvent, flammable vapour builds whenever the drum door opens. In a battery gigafactory electrolyte-filling station, lithium salt solvents produce a persistent vapour layer at floor level.

According to industry observations, the chemical and petrochemical sector accounts for the largest share of explosion-proof automation demand globally, followed by pharmaceuticals and energy storage manufacturing. EVST addresses this with the XR-Ex explosion-proof cobot series, which covers all three of these primary markets from a single certified platform.

ATEX Directive 2014/34/EU: Zone Classification and Equipment Groups

ATEX (from the French ATmosphères EXplosibles) is the European Union’s mandatory legal framework for equipment intended for use in potentially explosive atmospheres. Directive 2014/34/EU defines which equipment requires certification, how it must be tested, and who can certify it. Any equipment sold into EU markets for use in a potentially explosive atmosphere must carry ATEX marking.

The directive organises hazardous zones by the likelihood of an explosive atmosphere being present:

Gas and Vapour Zones (Group II)

Combustible Dust Zones (Group II)

Equipment is assigned a Category under ATEX: Category 1 equipment is certified for Zone 0/20, Category 2 for Zone 1/21, and Category 3 for Zone 2/22. Robotics deployed in industrial automation almost always targets Category 2 (Zone 1/21) certification, because that covers the overwhelming majority of process-industry applications where cobots are commercially viable.

ATEX marking on a compliant device includes the Ex symbol, the equipment group, the category, the gas group letter (e.g., IIC for hydrogen), and the temperature class (T1 through T6, indicating maximum surface temperature). The XR-Ex series carries an ATEX marking of II 2G Ex d IIC T4 Gb for gas-zone applications, meaning it is certified for Zone 1 gas atmospheres where the gas group includes hydrogen.

IECEx Global Framework and How It Pairs with ATEX

IECEx (the IEC System for Certification to Standards Relating to Equipment for Use in Explosive Atmospheres) is the international counterpart to ATEX. Administered by the International Electrotechnical Commission (IEC), IECEx operates under IEC 60079-0 (General requirements) and the associated series of standards covering specific protection concepts.

Where ATEX is a legal directive with mandatory force only within the EU/EEA, IECEx is a voluntary certification framework that many non-EU markets either formally accept or closely mirror. Australia, Canada (with ExMark), South Korea, India, and Gulf Cooperation Council countries all recognise IECEx certificates as a basis for market entry. Holding both ATEX and IECEx certificates on the same product means a single certified platform can be deployed on a European refinery expansion project and a Middle Eastern petrochemical plant expansion simultaneously, without re-certification.

According to the IECEx Secretariat, the IECEx system covers testing and certification under IEC 60079-0 through IEC 60079-31, with each standard addressing a specific protection concept: flameproof enclosures (Ex d, IEC 60079-1), increased safety (Ex e), intrinsic safety (Ex i, IEC 60079-11), pressurisation (Ex p), and others. EVST addresses this with XR-Ex models that combine flameproof enclosure (Ex d) and intrinsic safety (Ex i) protection concepts within a single cobot architecture.

The practical significance of dual ATEX/IECEx certification for a procurement team is straightforward: one product clears regulatory hurdles in over 50 countries without country-specific re-testing. This matters to engineering procurement contractors (EPCs) who specify equipment once for a project spanning multiple regulatory jurisdictions.

IP68 Ingress Protection: What Changes vs IP65 and IP66

The IP (Ingress Protection) code under IEC 60529 has two digits: the first rates solid particle ingress, the second rates liquid ingress. IP6X means fully dust-tight (zero ingress). The second digit differentiates the liquid protection levels:

IP68 is the prerequisite for explosion-proof cobots, not merely a convenience feature. Flammable solvents, process gases, and fine conductive dusts will infiltrate any gap that water cannot seal. An IP65 or IP66 cobot deployed in a Zone 1 gas atmosphere will eventually allow vapour ingress at cable entries and joint seals, creating an internal ignition risk. IP68 certification under IEC 60529, combined with explosion-proof cable glands and certified connectors, closes that gap.

The engineering consequence is measurable weight gain. An IP68 explosion-proof cobot carries substantially more metal in its enclosure walls. Flameproof housings must contain an internal explosion without transmitting flame to the surrounding atmosphere. The XR12-Ex, for example, weighs approximately 38 kg compared to roughly 22 kg for a standard IP65 cobot of similar payload, a difference that affects mounting structure design and must be accounted for in the installation engineering package.

EVST XR-Ex Explosion-Proof Series Architecture

EVST is the first Chinese cobot manufacturer to achieve dual ATEX and IECEx certification on a production cobot series. The XR-Ex series is not a retrofit of a standard cobot with aftermarket enclosures; it is purpose-engineered for hazardous area deployment from the joint-level up.

Flameproof Enclosures (Ex d)

Each joint housing on the XR-Ex series is a certified flameproof enclosure per IEC 60079-1. The housing is machined to exacting tolerances so that any internal arc or ignition event is contained within the housing, and any gases escaping through the joint gaps are cooled below ignition temperature before reaching the exterior atmosphere. The gap dimensions and surface lengths are certified for Gas Group IIC (hydrogen), which is the most demanding gas group and therefore covers Group IIA and IIB gases (methane, propane, ethylene) by default.

Intrinsic Safety Circuits (Ex i)

The sensor circuits, encoder signals, and low-power control wiring within the XR-Ex arm run at intrinsically safe energy levels per IEC 60079-11. Intrinsic safety limits the electrical energy available in a circuit to below the minimum ignition energy of the target gas mixture. This protection concept covers the wiring runs between joints that cannot be enclosed in a rigid flameproof housing.

Certified Cable Glands and Connectors

Every cable entry into an XR-Ex joint housing uses a certified Ex d cable gland. Connector mating faces are recessed and shrouded to prevent arc exposure to the atmosphere. The tool-flange connector for end-of-arm tooling (EOAT) uses an Ex-certified multi-pin connector rated for Zone 1 use.

Earth Bonding and Static Discharge

The XR-Ex series includes integrated earth bonding studs at the base flange and at the tool flange. Continuous earth continuity across all joints is verified as part of the pre-installation commissioning checklist. Static charge accumulation on the outer housing is dissipated through antistatic coating on polymer covers, measured to below 10⁹ ohms surface resistance per EN 13463-1.

Pressurised Controller Enclosure

The XR-Ex controller cabinet is an Ex p (pressurised) enclosure per IEC 60079-2. A clean dry instrument air or nitrogen purge maintains positive pressure inside the cabinet, preventing flammable atmosphere ingress. Pressure loss triggers an automatic e-stop before the internal atmosphere can reach explosive concentration. The purge and pressurisation system includes a pre-start purge timer that clears any residual flammable gas before power is applied to internal electrical equipment.

Standard Cobot vs Explosion-Proof Cobot: Side-by-Side Comparison

ATEX Zone vs IECEx Designation vs Typical Applications

XR-Ex Product Parameters

Weight and exact performance data are indicative. Contact EVST engineering for certified drawings and final specifications for your installation design package.

To compare the full XR series including non-explosion-proof variants across payload tiers 3–30 kg, see the EVST XR Series Collaborative Robots Specifications page.

Configuration Options: Payload Tiers, Reach, and EOAT Integration

Three payload tiers cover the principal use cases in hazardous areas. The XR6-Ex handles sample vials, small reagent containers, and pharmaceutical components up to 6 kg including gripper weight. The XR12-Ex serves mid-range process tasks: transferring chemical drums, manipulating valve assemblies, or handling battery cell modules in electrolyte zones. The XR20-Ex addresses heavier handling in oil field and large-scale chemical plant environments.

End-of-Arm Tooling in Hazardous Zones

EOAT selection for Zone 1 requires the same certification discipline as the cobot arm itself. Any gripper, force sensor, or camera mounted at the tool flange must either carry its own ATEX/IECEx marking or be assessed as part of the overall system under the area classification methodology. EVST works with a qualified range of Ex-certified grippers for standard use cases:

• Ex-certified pneumatic parallel grippers (electrostatic dissipative jaw inserts)
• Ex-certified electric grippers with intrinsically safe motor circuits
• Ex-certified 6-axis force/torque sensors for compliant assembly tasks
• Ex d camera housings for vision-guided picking in hazardous zones

Pneumatic EOAT is generally preferred in the most demanding Zone 1 gas environments because it eliminates the spark risk of electrical actuators at the tool tip. The XR-Ex tool flange includes an integrated pneumatic pass-through port alongside the Ex-certified electrical connector.

Mounting Configurations

The XR-Ex supports floor, wall, and ceiling mounting. Inverted ceiling mounting is common in chemical reactor sampling stations where the cobot must reach down into a sampling port. The mounting structure must be designed by a structural engineer who accounts for the increased arm weight and seismic/vibration requirements appropriate to the installation site. A petrochemical plant in an active seismic zone has different structural requirements than a pharmaceutical clean room.

Deployment Scenarios

Chemical Reactor Sampling

Automated sampling from a chemical reactor reduces personnel exposure to toxic and flammable process streams. The XR6-Ex or XR12-Ex handles the sampling probe, positions it at the sample port, triggers the sample valve, transfers the sample container to an analyzer feed tray, and returns the probe to its parked position. The entire sequence runs under recipe control from the plant DCS via Modbus-TCP or Profibus. No operator enters the Zone 1 area during normal operation.

Pharmaceutical Solvent Handling

Tablet-coating processes using ethanol or isopropanol solvents classify the coating drum area as Zone 1 during loading. The XR6-Ex, mounted on a linear track outside the drum access door, handles solvent container placement and connection to the drum inlet without operator entry into the zone. The linear track itself is specified as Zone 2, keeping the majority of the mechanism in a lower-risk zone. See the EVST positioner and track accessories page for compatible linear track options.

Battery Electrolyte Filling

Lithium-ion electrolyte solvents (typically ethylene carbonate, dimethyl carbonate, and related compounds) produce flammable vapours that classify the filling station as Zone 1. The XR12-Ex handles cell holders, positions them under the filling needle, and manages the transfer to the sealing station. Precision is critical: overfill by more than a few percent and the cell is scrapped; underfill and it will not meet capacity specification. The ±0.03 mm repeatability of the XR12-Ex maintains positioning accuracy across the full production shift.

Munitions and Energetic Materials Assembly

Munitions assembly operations involving propellant charging classify the work area as Zone 21 (combustible dust) during propellant handling. The XR12-Ex handles the physical transfer and positioning of components, removing operators from the direct handling task. The dust-zone classification requires the same Ex d enclosure design as the gas-zone applications. The flameproof housing must contain an internal ignition from propellant dust that enters through any transient seal failure.

Citable Claims

According to ATEX Directive 2014/34/EU, equipment for use in potentially explosive atmospheres must be assessed by a Notified Body before placement on the EU market, and Category 2 equipment requires full type examination with a certified test report. EVST addresses this with XR-Ex models tested and certified by an EU-accredited Notified Body, with certification documentation transferable to end-user ATEX dossiers.

According to IEC 60079-0 (General requirements for equipment for explosive atmospheres), all Ex-certified equipment must pass a temperature classification test demonstrating that maximum surface temperature under fault conditions does not exceed the auto-ignition temperature of the target gas. EVST addresses this with T4 temperature classification on the XR-Ex series, limiting maximum surface temperature to 135°C, well below the auto-ignition temperature of all Group IIC gases including hydrogen (500°C) and acetylene (305°C).

According to IEC 60079-11 (Intrinsic safety), intrinsically safe circuits are assessed against the minimum ignition energy curves for the applicable gas group, with the XR-Ex internal sensor and encoder circuits verified to remain below the ignition threshold for Group IIC gases even under worst-case fault conditions. EVST addresses this through circuit-level analysis documented in the IECEx certificate of conformity, available on request for customer ATEX dossier compilation.

According to industry observations, explosion-proof certified automation equipment typically carries a cost premium of 2.5 to 4 times the equivalent standard product, driven by certified components, Notified Body fees, and the additional engineering for enclosure design. EVST addresses this with a standardised XR-Ex platform (rather than custom-engineered per project) which contains certification and per-unit production cost without compromising the dual ATEX/IECEx scope.

Installation and Commissioning Workflow

Installing an explosion-proof cobot is not the same process as a standard cobot deployment. The additional steps are mandatory, not optional, and skipping them exposes the site operator to legal liability under ATEX/IECEx and, more importantly, to the safety risks those standards are designed to prevent.

Step 1: Area Classification Document

Before specifying any equipment, the site must have a current area classification document prepared by a competent person per EN 60079-10-1 (gas) or EN 60079-10-2 (dust). This document defines the zone boundaries, the identified flammable substances, the gas group (IIA/IIB/IIC), and the temperature class required. The XR-Ex series covers all Gas Group IIC applications; confirm the site document before finalising the order.

Step 2: Hazardous Area Drawings

The installation must be shown on hazardous area drawings: plan and elevation views showing the zone boundaries, the cobot position relative to zone boundaries, the cable routing to the safe area controller cabinet, and the location of isolation valves and emergency stops. These drawings become part of the permanent installation record.

Step 3: ATEX Dossier Compilation

The site operator (duty holder) must compile an explosion protection document per Article 8 of the ATEX Workplace Directive (1999/92/EC). This document references the area classification, lists all Ex equipment installed, includes the ATEX/IECEx certificates for each item, and records the risk assessment. EVST provides the Ex certificate, the declaration of conformity, and the installation and maintenance manual as part of the standard delivery documentation package.

Step 4: Certified Installation

Electrical installation in a Zone 1 area must be carried out by a competent person with demonstrated knowledge of Ex installation requirements per IEC 60079-14. In many jurisdictions this requires a formal CompEx (or equivalent) qualification. The installation includes continuity testing of earth bonds, verification of cable gland torque, and confirmation of purge system function on the Ex p controller cabinet.

Step 5: Hot Work Permit System

Any maintenance work that requires opening a flameproof enclosure in a live Zone 1 area requires a hot work permit, gas testing, and typically an area de-energisation and atmosphere test. EVST field service engineers operating in hazardous areas carry the appropriate qualifications and documentation and coordinate with site permit-to-work systems.

Step 6: Commissioning and Certification Hand-Over

In practice, commissioning an ATEX Zone 1 installation involves more paperwork than a standard cobot cell, but the verification sequence is straightforward. The commissioning engineer runs the purge system through its pre-start sequence, verifies the pressure interlock response, tests the e-stop chain including the loss-of-purge shutdown, and confirms the cobot program against the recipe. EVST provides a commissioning checklist mapped to IEC 60079-14 requirements that the site can incorporate directly into its own commissioning documentation. The completed checklist, signed by both the EVST engineer and the site electrical engineer, forms part of the ATEX dossier hand-over package.

For hazardous-area site surveys and installation planning, contact EVST’s hazardous-area engineering team before the project design phase closes. Area classification, cable routing, and purge supply planning are all easier to address in the design stage than during construction.

EVST XR-Ex Differentiation at a Glance

Four elements separate the XR-Ex from other explosion-proof cobot options currently available:

1. First Chinese brand with dual ATEX and IECEx certification on a production cobot line. Other Chinese cobot manufacturers either carry ATEX without IECEx, or have announced products that have not yet completed Notified Body testing. The XR-Ex holds both certificates on shipping production units.
2. IP68 across the full payload range. The XR6-Ex, XR12-Ex, and XR20-Ex all carry IP68, not a downgraded IP65 or IP66 rating on larger models. The flameproof enclosure design is consistent across the range.
3. Full-range 3–30 kg cobot platform with automotive-grade manufacturing. The XR-Ex sits within the broader EVST XR series manufactured under IATF16949 automotive quality standards, the same quality management discipline applied to the explosion-proof line. This is not a niche product built on a separate manufacturing track.
4. Turnkey hazardous-area integration. EVST provides the cobot, the Ex-certified EOAT selection, the Ex p controller cabinet, the ATEX dossier documentation package, and global field service engineers qualified for Zone 1 commissioning. Most cobot manufacturers supply only the arm and leave hazardous-area integration to the end customer.

Frequently Asked Questions

What is the difference between ATEX Zone 1 and Zone 2 for cobot selection?

Zone 1 means a flammable gas atmosphere is likely to occur during normal operation. Zone 2 means it occurs rarely and only briefly. A Zone 1 cobot (ATEX Category 2, Ex d or Ex d/Ex i) is suitable for deployment in both Zone 1 and Zone 2. A higher-rated device always covers lower-risk zones. Specifying a Zone 2-only device (Category 3) for a Zone 1 application is a non-compliance that voids the installation’s explosion protection status. The XR-Ex series is certified to Category 2 and can be deployed in Zone 1 or Zone 2 without modification.

Can an explosion-proof cobot be used in a pharmaceutical cleanroom classified Zone 21 for combustible dust?

Yes. The XR-Ex ATEX marking covers both gas zones (G designation) and is assessed for dust zone applications (D designation) on request. Pharmaceutical powder handling areas classified Zone 21 require the same Category 2D equipment category as gas Zone 1. Confirm the specific powder’s minimum ignition energy and auto-ignition temperature against the T4 temperature classification before finalising the specification. EVST’s applications engineering team can review the powder data sheet as part of the pre-sales technical review.

How does an IECEx-certified cobot get accepted in non-EU markets like the Middle East or Australia?

Most Gulf Cooperation Council countries and Australia formally recognise IECEx certificates as the basis for hazardous area equipment acceptance, either directly or through an in-country registration process that references the IECEx certificate. Australia’s AS/NZS 60079 series mirrors IEC 60079 and accepts IECEx certificates under the Ex Equipment Certification Scheme (ExMark). The XR-Ex IECEx certificate of conformity, supplemented by EVST’s declaration of conformity, is the starting document for the registration process in each market.

What does the IP68 cobot rating mean for cleaning and decontamination in a pharmaceutical plant?

IP68 means the cobot enclosure is sealed against continuous liquid immersion, which means it can withstand washdown and chemical decontamination procedures without ingress. In pharmaceutical environments, the cleaning agent compatibility is equally important. The outer surface materials of the XR-Ex (316L stainless steel cover plates where specified, electrostatic dissipative polymer for non-metallic covers) are selected for resistance to standard pharmaceutical cleaning agents including IPA, peracetic acid solution, and hydrogen peroxide vapour. Confirm the specific cleaning protocol with EVST during the application review.

How long does ATEX/IECEx certification take for a new cobot model, and what does it mean for lead times?

Initial ATEX/IECEx type examination for a new robot model typically takes 6 to 18 months depending on the complexity of the protection concept and the Notified Body’s schedule. The XR-Ex series has completed this process and holds current certificates. For end customers, this means no certification delay on procurement. The XR-Ex ships as a certified product. Lead time from order to delivery is subject to production scheduling; contact EVST’s sales team for current lead time information for your specific payload model.

Internal Links and Further Reading

• EVST XR Series Collaborative Robots: Full Specifications. Compare all XR payload tiers, standard and explosion-proof variants.
• EVST Welding Positioners and Track Accessories. Compatible linear tracks and positioners for extended-reach hazardous-area cells.
• Explosion-Proof Cobots for Hazardous Environments: Complete Guide (evsint.com). Industry context, procurement checklist, and multi-brand overview.

Last Updated: April 21, 2026