Explosion Proof Switches for Hazardous Environments

Brian Craig

August 06, 2025

When working in hazardous environments, such as oil & gas, chemical processing, mining, or wastewater treatment, safety isn’t optional. Equipment must meet strict standards to prevent ignition of flammable gases, vapors, or dust. That’s where explosion-proof switches come in. These rugged, sealed devices play a critical role in control and automation, ensuring reliable operation even under extreme conditions.

In this guide, we’ll explore the best explosion-proof switches for hazardous applications, discuss key features to look for, and recommend proven options trusted by industry professionals.

What Is an Explosion-Proof Switch?

An explosion-proof switch is a specially designed electrical switch that can safely operate in explosive atmospheres. Unlike standard switches, it is built to contain any internal explosion and prevent it from igniting the surrounding atmosphere.

These switches often carry certifications like ATEX, IECEx, FM, or CSA, ensuring compliance with global safety standards for use in Zone 1/2 (gas) and Zone 21/22 (dust) environments.

Types of Explosion-Proof Switches for Industrial Use

Let’s break down some of the most commonly used explosion-proof switches in hazardous industries:

1. Explosion-Proof Level Switch

An explosion-proof level switch detects fluid levels in tanks, vessels, or pipelines within hazardous zones. These are ideal for oil & gas, chemical, and pharmaceutical industries where flammable liquids are stored.

Top Features:

Vibrating, capacitive, or float-based technology
Intrinsically safe wiring options
Corrosion-resistant housing

Popular Models:

VEGA VEGASWING, VEGAVIB, and VEGAPOINT Series
ERH Series Level Switches
Explore Explosion-Proof Level Switches ›

2. Explosion-Proof Limit Switch

An explosion-proof limit switch provides position feedback in actuators or moving equipment. Common in refineries, conveyor systems, and process plants.

Top Benefits:

Withstands high vibration and shock
Flameproof or encapsulated enclosure
Dust-tight sealing for explosive dust areas

3. Explosion-Proof Float Switch

These switches are perfect for liquid level control in tanks, sumps, or wells located in classified zones.

Key Advantages:

Simple design, low maintenance
Suitable for high-viscosity or dirty liquids
Available in stainless steel for corrosion resistance

4. Explosion-Proof Differential Pressure Switch

Used to monitor pressure differences across filters, pumps, or valves, these switches are vital in combustion systems and chemical processes.

Must-Have Features:

Dual pressure inputs
Hermetically sealed contacts
Flameproof enclosures with ATEX or CSA ratings

5. Industrial Pressure Switch (Explosion Proof Rated)

This general-purpose pressure switch type is built for broad industrial use in explosive zones.

Applications:

Compressors and pumps
Natural gas pipelines
Petrochemical process systems

Comparison Table: Top Explosion-Proof Switches

Switch Type	Best For	Certifications	Temp Range
Explosion-Proof Level Switch	Tanks, chemical vessels	ATEX, IECEx, FM	-40 to 150°C
Explosion-Proof Limit Switch	Valves, conveyors, actuators	CSA, UL, FM	-25 to 125°C
Explosion-Proof Float Switch	Sumps, wastewater, oil tanks	ATEX, UL	-20 to 100°C
Differential Pressure Switch (Ex)	Filters, blowers, pressure tanks	FM, CSA, ATEX	-25 to 120°C
Flameproof Pressure Switch	Pipelines, combustion systems	ATEX, CSA	Up to 200°C

How to Choose the Right Explosion-Proof Switch

Choosing the right switch involves more than just picking a certified product. Here's what users should consider:

Understand the Hazardous Zone Classification

Know whether you're in Zone 0, 1, or 2 (gas), or Zone 20, 21, or 22 (dust).
Select Based on Media Type

Liquid → Float or level switch
Gas → Pressure or limit switch
Dust → Encapsulated or flameproof types

Match Environmental Requirements

Check temperature, pressure, material compatibility, and ingress protection (IP rating).
Look for Third-Party Certifications

Ensure your product is compliant with ATEX , IECEx, FM, or CSA.
Consult With a Specialist

Don’t guess—talk to someone who understands hazardous environments.
Contact TTS Experts ›

Certifications Glossary: What Do They Mean?

ATEX vs IECEx – What’s the Difference?

ATEX: European directive for explosive atmospheres
IECEx: Global certification from the International Electrotechnical Commission
FM/CSA: North American standards for explosion protection
All indicate that a product is safe to use in hazardous, flammable environments.

FAQs: Explosion-Proof Switches

Q1. What does “explosion-proof” mean in switches?

It means the device is built to contain internal sparks or flames and prevent them from igniting the external atmosphere.

Q2. Can I use a flameproof switch in a dust zone?

Yes, but the product must be rated for both gas and dust classifications.

Q3. What’s the difference between flameproof and intrinsically safe?

Flameproof: Contains the explosion
Intrinsically safe: Prevents sparks or heat from being generated

Q4. How often should these switches be maintained?

Explosion-proof switches should be inspected annually and more often in high-risk environments.

Q5. Are all industrial switches explosion-proof?

No, only those explicitly rated and certified for hazardous zones.

Why Choose The Transmitter Shop (TTS)?

With over 30 years of experience, The Transmitter Shop offers:

A wide range of explosion-proof level switches, pressure switches, float switches, and more
Top brands like VEGA, Foxboro, Rosemount and Applisens
Competitive pricing and two-year warranties
Fast shipping and knowledgeable support

Whether you’re upgrading an existing system or specifying components for a new build, our experts are here to help.