Hazardous Location Lighting

How to Choose Hazardous Location LED Lighting for Industrial Facilities

Hazardous location lighting must be suitable for the specific ignitable atmosphere and electrical classification of the installation area. Refineries, chemical-processing plants, fuel-handling facilities, and certain manufacturing environments can contain classified zones, but not every room within these buildings has the same requirements. Selection begins with the facility's documented hazardous-area classification, followed by the fixture's approved application, operating temperature, and electrical specifications. Light output and mounting style matter only after the equipment's suitability for the location has been established.

Quick Hazardous Location Lighting Selection Guide

• Class I, Division 2 process area: Compare luminaires with documented approval for the applicable gas or vapor hazards.
• Open industrial floor: Consider a compatible round hazardous-location LED high bay with suitable optics.
• Long process aisle: Review linear hazardous-location fixtures and their light distribution.
• Combustible-dust environment: Confirm the exact Class II or other required approval before selecting equipment.
• Unclassified high-ceiling area: Compare conventional LED high bay lights.

Class I, Class II, and Class III Hazardous Locations Explained

In the United States, the NEC Class and Division system distinguishes hazardous environments according to the materials present and their likelihood of creating an ignitable atmosphere.

• Class I: Locations involving flammable gases or vapors, such as certain petroleum-processing or solvent-handling areas.
• Class II: Locations involving combustible dust, including some grain-processing, chemical, and metal-powder operations.
• Class III: Locations involving ignitable fibers or flyings associated with certain textile and material-processing activities.

These classifications apply to specific areas, not automatically to an entire facility. A processing room may require hazardous-location equipment while an adjacent office remains unclassified.

Class I locations use gas Groups A through D, while Class II locations use dust Groups E through G. Equipment suitable for one group cannot automatically be substituted for another.

Selection rule: Obtain the facility's approved classification documentation before choosing a luminaire. Do not infer Class or Group from the building's industry alone.

Class I Division 1 vs. Division 2 LED Lighting

Division designations describe the conditions under which hazardous concentrations may be present.

Division 1 generally includes locations where an ignitable atmosphere can occur during normal operating conditions or under other specified circumstances.

Division 2 generally includes locations where hazardous substances are normally contained and ignitable concentrations are expected only under abnormal conditions, such as equipment failure or an accidental release.

For example, two areas within a chemical facility may have different classifications depending on how materials are handled and the conditions under which vapors could escape.

Westgate's EXPR hazardous-location fixtures include models documented for Class I, Division 2, Groups A, B, C, and D. That approval does not automatically establish suitability for Class I, Division 1 or Class II installations.

Equipment approved for Division 1 may be permitted in a Division 2 location of the same applicable Class and Group, but the reverse is not generally permitted.

Some industrial projects use the Zone classification system instead of Divisions. Zone and Division designations should not be treated as simple one-to-one equivalents. Match equipment to the classification system documented for the installation.

Hazardous Location Certifications, Temperature Codes, and Environmental Ratings

Hazardous-location approval must account for the relevant Class, Division or Zone, substance characteristics, and operating temperature. A product description stating "explosion-proof" is not sufficient evidence of suitability.

For example, the manufacturer identifies the Westgate EXPR-60W-50K under UL file E503444 for Class I, Division 2, Groups A through D. This information should be matched with the specific installation requirements and the product's current certification documentation.

Temperature classification is also important. The fixture's maximum surface temperature must be suitable for the ignition characteristics of the substances present. Check the applicable T-code, approved ambient-temperature range, and certification conditions.

Certain fixed Division 2 luminaires have exceptions to specific equipment-marking requirements. If a Group designation is not printed on the fixture, verify the permitted application in its certification documentation rather than assuming the rating is missing or unrestricted.

An IP66 or wet-location rating addresses environmental protection against dust and water under specified conditions. It does not establish hazardous-location approval.

Likewise, an ordinary LED vapor tight light cannot replace a required hazardous-location fixture solely because both have sealed housings.

Round vs. Linear Hazardous Location LED Lights

Once the equipment approval is established, the lighting layout determines whether a round or linear fixture is the better fit.

Westgate EXPR Round Hazardous Location High Bays

The EXPR Series uses compact round housings and can suit open industrial areas where light needs to reach a broad working surface.

For example, the Westgate EXPR-60W-50K is a 60W model producing 8,580 lumens at 5000K, with a specified 120–277V input and 100-degree beam angle.

Other EXPR configurations provide different outputs and electrical ratings. A higher-wattage model should not be chosen without checking the required illumination level and mounting height.

Westgate EXPL Linear Hazardous Location High Bays

The EXPL Series uses elongated housings that can suit production lines, aisles, and rectangular industrial work zones.

For example, the Westgate EXPL-80W-50K is specified at 80W, 10,800 lumens, and 5000K with a 120–277V electrical configuration.

The EXPL range also includes different outputs and a separately specified 480V configuration.

Selection rule: Choose between round and linear fixtures by optical distribution, mounting conditions, and work-area layout after confirming the necessary hazardous-location approvals.

Hazardous Location Lighting: Lumens, Voltage, and Mounting Height

Wattage measures electrical consumption, while lumens describe light output. The required brightness depends on the work being performed, ceiling height, fixture spacing, and obstacles such as equipment or storage racks.

A large processing area may need a different lighting distribution from a narrow maintenance aisle. Use manufacturer photometric data to evaluate illumination at the working surface rather than selecting fixtures by wattage alone.

Input voltage must also match the electrical system. A fixture designed for 480V operation should not be treated as interchangeable with a 120–277V model.

When comparing fixtures, verify:

• Delivered lumens: Required light output for the application.
• Optical distribution: Coverage and fixture spacing.
• Input voltage: Compatibility with the installed supply.
• Ambient temperature: Suitability for expected operating conditions.
• Mounting arrangement: Approved supports, brackets, and orientation.

The luminaire's environmental rating and hazardous-location approval must both remain valid in the complete installation.

Hazardous Location Light Accessories: Wire Guards and Replacement Lenses

Some products in this collection are replacement accessories rather than complete lighting fixtures.

For example, Westgate EXPR-30-60W-WGF is a flat wire guard intended for compatible EXPR fixtures in the 30W and 60W configurations. Similarly, EXPR-30-60W-LD is a dome lens, not an LED luminaire.

These part numbers identify accessory compatibility. Their wattage ranges do not describe the electrical consumption of the accessory.

Before purchasing a guard or replacement lens, match the exact EXPR fixture series, housing size, and manufacturer's approved component.

Do not substitute a similar-looking aftermarket lens or guard without confirming its suitability for the certified luminaire assembly.

Hazardous Location Lighting Installation: Wiring Methods and Equipment Compatibility

A certified hazardous-location luminaire must be installed with wiring methods and connection components suitable for the area classification.

Depending on the location and applicable NEC requirements, the installation may need specified conduit systems, sealing fittings, grounding and bonding arrangements, or other protective measures.

For example, an ordinary cable connector or enclosure is not automatically acceptable in a Class I, Division 2 location. The approved wiring method and equipment-entry arrangement must be verified as part of the complete installation.

Where electrical equipment is installed outside the classified area, suitable NEMA electrical enclosures may address environmental protection requirements. A NEMA enclosure rating alone does not authorize installation within a hazardous location.

Electrical installation, inspection, and maintenance should be completed by qualified personnel using the manufacturer's instructions, documented area classification, and applicable electrical requirements.

Ordering Hazardous Location Lighting for Industrial Projects

For larger industrial projects, prepare a fixture schedule using the approved hazardous-area documentation. Include the exact manufacturer model and required certification rather than ordering from a general product description.

Record the following information:

• Documented Class, Division or Zone, and applicable Group
• Required temperature classification and ambient rating
• Exact fixture series and manufacturer part number
• Wattage, lumens, voltage, and photometric requirements
• Mounting height, orientation, and approved installation hardware
• Environmental protection requirements
• Compatible wire guards, lenses, or other accessories
• Project quantities and supporting certification documents

Eligible business customers can review Lumera Electric's trade account options for industrial purchasing.

For larger orders, request a hazardous-location lighting quote with the fixture schedule, part numbers, and project requirements.

Hazardous Location Lighting FAQs

What is the difference between Class I Division 1 and Division 2 lighting?

Class I, Division 1 and Division 2 identify different conditions involving flammable gases or vapors. Division 1 generally includes hazards that can occur during normal operation, while Division 2 generally addresses specified abnormal conditions. A Division 2 luminaire cannot automatically be installed in a Division 1 location. Match the exact fixture approval to the documented area classification.

Is hazardous location lighting the same as explosion-proof lighting?

Not necessarily. Hazardous-location lighting is the broader category of equipment approved for specified classified environments. Explosion-proof construction is one protection method used in certain applications. Other approved protection approaches may be permitted depending on the location. The product's listing and intended classification determine its suitability, not the marketing term alone.

Can Class I Division 2 LED lights be used in Class II locations?

Only when the exact equipment has the required Class II approval or another specifically permitted basis for installation. Class I concerns flammable gases and vapors, while Class II concerns combustible dust. Approval for one does not automatically establish approval for the other. Verify the applicable classification and certification before ordering.

What does the temperature code mean on hazardous location lighting?

A temperature code identifies an equipment surface-temperature classification under specified conditions. It helps determine whether the fixture is suitable for the ignition characteristics of the hazardous substance present. The approved ambient-temperature range also matters. Check the current product marking and certification documentation for the applicable temperature requirements.

Is an IP66-rated LED fixture suitable for hazardous locations?

Not on the basis of its IP rating alone. IP66 addresses specified resistance to dust and powerful water jets. Hazardous-location equipment must also meet the approval requirements for the applicable ignitable atmosphere. A weather-sealed fixture with no suitable hazardous-location approval cannot replace properly approved equipment.

Are EXPR wire guards and dome lenses complete LED lights?

No. Westgate EXPR wire guards and dome lenses are accessories designed for specified compatible luminaires. They do not include the complete LED lighting system. Check the accessory part number against the exact fixture model and confirm that the resulting assembly remains approved for the intended installation.