Underground and hazardous-area crews buy lighting and head protection together, because the lamp has to mount on the helmet and, in some areas, has to be certified so that it cannot ignite the atmosphere. This guide explains how to read the markings on intrinsically safe (IS) equipment and what to check on cap lamps, torches and helmets with lamp brackets, using our product listings and the IEC 60079 equipment groups. It is general information. Your site's hazardous area classification and approval rules decide what you may use.
What does intrinsically safe mean?
Intrinsic safety is a way of designing electrical equipment so that any spark or heat it can produce has too little energy to ignite an explosive atmosphere. The method is covered by IEC 60079-11 and is marked Ex i, with a level of protection of ia, ib or ic. It is a certification of the design. It does not describe how bright, tough or waterproof a light is, and a lamp can be rugged, waterproof and anti-static without being intrinsically safe.
How do you read an Ex marking?
| Part of the marking | What it tells you |
|---|---|
| Ex | The equipment is certified for explosive atmospheres. |
| ia, ib, ic | The level of intrinsic safety. ia suits Zone 0, ib suits Zone 1 and ic suits Zone 2. |
| I or II | The equipment group. Group I is for mines susceptible to firedamp. Group II is for other explosive gas atmospheres. |
| IIA, IIB, IIC | The gas sub-group within Group II. IIC covers the most easily ignited gases, including hydrogen. |
| T4, T3 | The temperature class, which is the highest surface temperature the equipment can reach. T4 is 135°C and T3 is 200°C. |
| Ma, Ga, Gb | The equipment protection level. Ma is for mines, Ga suits Zone 0 and Gb suits Zone 1. |
Zones describe how often an explosive atmosphere is present: Zone 0 means continuously or for long periods, Zone 1 means likely at times in normal operation, and Zone 2 means unlikely and only for short periods. Examples from our listings:
- The Nightstick IS Dicata headlamp lists Ex ia op is IIC T4 Ga: intrinsically safe, Group II, gas sub-group IIC, temperature class T4, suited to Zone 0.
- The 3M Versaflo TR-819A PAPR kit lists Ex ia I Ma: intrinsically safe and Group I, for mines.
- The Sundström SR500 EX fan unit lists II G Ex ib IIA/IIB T3 Gb: Group II, suited to Zone 1.
Mines and surface plant are different certifications. The Nightstick headlamp listings that give the full marking state Group II (IIC) certifications. If your mine requires Group I equipment, you need a unit marked for it. Ask your site's electrical engineer which markings are acceptable before you order.
What should you check on a cap lamp?
- Light output. Our Maxisafe cordless cap lamp lists a 235 lumen, 2.22 W main light and 13,000 lux. Lumens measure total light output. Lux measures the light reaching a surface at a given distance, so a lux figure only means something when the distance is stated.
- Battery and run time. The same lamp has a 6.8 Ah lithium-ion battery, a 4 hour charge time and a rated 1,200 charge cycles.
- Housing. It lists an anti-static housing and IP68 water resistance.
- Certification. The listing does not state an intrinsically safe rating. If your area requires IS lighting, use a lamp whose certificate says so. Anti-static does not mean intrinsically safe.
- Mounting. The lamp mounts to a hard hat, so check your helmet has a lamp bracket that suits it.
Which intrinsically safe torches and headlamps do we supply?
Details are from the manufacturer information on each listing, and the certifications are as stated there. Class and Division is the North American way of classifying hazardous locations; Zone is the IEC way.
| Light | What the listing says | Certification stated |
|---|---|---|
| Nightstick IS USB Dual-Light Headlamp (Zone 0) | Rechargeable Li-Polymer. 160 lumens. Spotlight and floodlight, USB magnetic charge cord, hard hat strap. | cULus, ATEX, INMETRO, KOSHA and IECEx; Ex ia IIC T4 Ga |
| Nightstick IS Dicata USB Rechargeable Dual-Light Headlamp (Zone 0) | Li-Ion rechargeable. IP67. Spot, flood or both at once. Magnetic USB charging. | cULus, ATEX and IECEx; Ex ia op is IIC T4 Ga |
| Nightstick dual-function headlamp | Three AAA batteries included, not rechargeable. 180 lumens on high, 90 on low. IP67. 2 m drop rating. 6 hours on high, 19 on low. | cETLus, ATEX, IECEx and INMETRO |
| On Site Safety Torrent torch | 1 W LED. Four AA batteries. IPX7. Escape valve for hydrogen build-up. Clips to a helmet peak or 30 mm slot. | ATEX, IECEx and UL; Class 1 and 2, Division 1 |
| Pelican 3415M right-angle light | 336 lumens. Spot and flood LEDs. Magnetic clip. | Intrinsically safe, Class I, II and III, Division 1 |
More lights, including scene lights and angle lights, are in our Nightstick range.
What should a miners' helmet have?
- A lamp bracket. Helmets we supply with a metal lamp bracket include the MSA V-Gard 500 full brim, the 3M HH40M full brim (box of 20), the Sureguard Tuffgard miners cap TG56MLV (vented, with a rear leather clip, box of 20) and the Maxisafe Tuffgard vented hard hat.
- The standard. The 3M HH40M and Maxisafe Tuffgard listings state AS/NZS 1801:1997 (the previous edition; AS/NZS 1801:2024 is now current), and the HH40M is listed as Type 1.
- Attachments. The Sureguard Tuffgard accepts most 25 mm and 30 mm attachments, such as cap-attachable earmuffs and visor holders.
- Replacement dates. Maxisafe's Tuffgard listing gives 3 years from first use for the helmet and 2 years for the harness. Follow the maker's guidance for any helmet.
For the belt, the MSA Gravity miners belt with shoulder straps is designed to carry MSA self-rescuers, has stainless steel buckles for corrosive conditions and is listed with a harness configuration certified to AS/NZS 1891.1:2007 (the previous edition; AS/NZS 1891.1:2020 is now current). Miners' harnesses include the MSA Gravity and the 3M DBI-SALA Delta.
What should you check before you buy?
- Find out your area's classification and approval requirements: zone, group and gas or dust type.
- Match the certificate to it: Group I or II, ia, ib or ic, and the temperature class.
- Check the helmet has a lamp bracket that fits your lamp.
- Check the battery type and charger, the run time against your shift, and the ingress rating.
- Check who will maintain the equipment and how it will be inspected.
Setting up a crew? Contact our team with the area and the approvals your site needs, and we will help match the equipment.
Sources: the equipment groups and zones in CML's hazardous area guide for ATEX and IECEx, which follows IEC 60079-0 and IEC 60079-11; and the manufacturer information on each 1st Safety product listing. This guide summarises these sources in our own words. It is general information, not legal advice.
1st Safety is based in Auburn, NSW, and supplies AS/NZS-compliant PPE to trades, construction, and industrial businesses across Australia.
Frequently Asked Questions
What is the difference between a cap lamp and an intrinsically safe torch?
A cap lamp is a head-mounted light that fits a helmet bracket. Intrinsic safety is a certification that can apply to any light, including a cap lamp or a torch. A light is only intrinsically safe if its certificate says so.
Is the Maxisafe cordless cap lamp intrinsically safe?
The listing states an anti-static housing and IP68 water resistance, and does not state an intrinsically safe rating. If your area requires intrinsically safe lighting, choose a lamp whose certificate says it is.
What does Zone 0 mean?
Zone 0 is an area where an explosive gas atmosphere is present continuously or for long periods. Equipment for it is marked ia and Ga.
What is the difference between Group I and Group II equipment?
Group I is electrical equipment for mines susceptible to firedamp. Group II is for other places with explosive gas atmospheres. Check which your site requires; the Nightstick headlamp listings that give the full marking state Group II (IIC) certifications.
Which of your lights are certified for Zone 0?
The Nightstick IS headlamps listed above state Zone 0 certification (Ex ia IIC T4 Ga). The On Site Safety Torrent torch lists ATEX, IECEx and UL certification, with Class 1 and 2, Division 1. Check each certificate against your site's zone and group.
Can any hard hat take a cap lamp?
Only a helmet with a lamp bracket, or one that accepts a suitable attachment. Several helmets we supply come with a metal lamp bracket, including the MSA V-Gard 500 full brim, the 3M HH40M, the Sureguard Tuffgard miners cap and the Maxisafe Tuffgard.
How long do hard hats last?
Follow the maker's replacement guidance. Maxisafe's Tuffgard listing gives 3 years from first use for the helmet and 2 years for the harness.
Can you supply a whole crew?
Trade pricing and account terms are available, so contact our team or call 0457 545 175. We're based in Sydney, with fast dispatch Australia-wide.