In high-risk environments like oil refineries, chemical plants, and underground mines, intrinsically safe (IS) devices serve as the frontline defense against ignition-related accidents. These devices are designed to operate safely in explosive atmospheres—but their safety only lasts as long as their integrity is preserved. That’s where routine, regulated maintenance plays a pivotal role.
This guide provides a detailed intrinsically safe device maintenance checklist tailored for field technicians, safety officers, and compliance managers. We also cover best practices, compliance standards, recommended products, and practical scheduling tips to help you maintain your equipment—and your peace of mind.
Don’t compromise on safety. Shop intrinsically safe devices built for harsh environments.
What Are Intrinsically Safe Devices and Why Do They Need Maintenance?
Intrinsically safe devices are engineered to limit energy (electrical or thermal) below the levels that could ignite a hazardous atmosphere. These devices are typically ATEX or IECEx certified for Zone 0, 1, or 2 environments and include:
Tablets and smartphones
Gas detectors
Cameras
Radios and communication tools
Sensors and instrumentation
Despite their rugged designs, IS devices are still vulnerable to environmental exposure, software decay, and mechanical fatigue. Neglecting maintenance can lead to:
Certification invalidation
Regulatory fines
Safety hazards
Unplanned downtime
A structured maintenance program ensures your equipment stays compliant, operational, and safe.
What Standards Govern Intrinsically Safe Device Maintenance?
International Guidelines
These globally recognized standards are critical for governing how IS devices should be maintained:
IEC 60079-17: Specifies inspection and maintenance procedures for electrical installations in hazardous areas.
IEC 60079-14: Details the selection, installation, and initial verification of electrical systems in explosive atmospheres.
IEC 60079-19: Outlines repair and overhaul procedures that preserve certification integrity.
NFPA 70 (NEC): U.S. National Electrical Code guidelines for hazardous (classified) locations.
What Happens If These Are Ignored?
Non-compliance can lead to:
Equipment failure and operational delays
Voided manufacturer warranties
Increased risk of ignition in flammable zones
Legal or financial penalties during audits or investigations
Intrinsically Safe Device Maintenance Checklist
Use this seven-part checklist to ensure thorough and compliant maintenance of your intrinsically safe devices:
1. Visual and Structural Inspection
Inspect for physical damage, dents, or warping of the device casing.
Verify that ATEX/IECEx labels and markings are legible.
Check housing for water ingress, cracks, or wear around joints and gaskets.
Examine protective covers, ports, and battery compartments for contamination.
Frequency: Monthly or before each use in extreme conditions.
2. Functional Testing
Power the device on and verify boot-up diagnostics.
Test buttons, touchscreens, and interfaces for responsiveness.
Run diagnostic tools provided by the manufacturer (e.g., Samsung Knox on Tab-Ex® models).
Confirm operation of communication systems: LTE, GPS, Wi-Fi, Bluetooth.
Validate response of safety alerts, LEDs, buzzers, or vibration motors.
Frequency: Quarterly or after each major firmware update.
3. Electrical Testing and Circuit Integrity
Measure voltage levels across input/output ports using IS-rated multimeters.
Conduct insulation resistance tests to detect deterioration.
Confirm grounding and bonding continuity where required.
Ensure there is no cross-wiring between IS and non-IS circuits.
Frequency: Annually, or after high-impact incidents or liquid exposure.
4. Battery and Power System Review
Check for battery swelling, corrosion, or leakage.
Use manufacturer-approved battery packs only—third-party batteries can void certification.
Monitor battery runtime—drop in performance may indicate deep-cycle degradation.
Inspect charging ports and accessories for wear and compatibility.
Frequency: Biannually for testing, every 18–24 months for replacement.
5. Firmware and Software Updates
Use OEM-approved software tools for firmware upgrades.
Check that OS versions (e.g., Android 13+, Windows 11) are compliant with enterprise security policies.
Revalidate functionality post-update—especially for communication and safety-critical apps.
Document version changes and release notes in the service log.
Frequency: As released by the vendor or based on IT policy cycles (quarterly recommended).
6. Calibration and Sensor Validation
For devices with measurement or detection capabilities (e.g., gas detectors, RFID sensors):
Calibrate according to manufacturer recommendations (often every 6–12 months).
Use traceable calibration tools or certified labs.
Verify baseline readings and setpoints against known standards.
Frequency: Every 6–12 months depending on device function and criticality.
7. Maintenance Documentation and Recordkeeping
Maintain a log with entries for each inspection, test, repair, and software change.
Include serial numbers, technician IDs, and timestamps.
File certificates of calibration, conformity, and repair.
Digitize records using CMMS (Computerized Maintenance Management Software) if possible.
Why It Matters: Provides a defensible maintenance history for audits and internal reviews.
Avoid certification loss and fines. Talk to our compliance experts for support.
How Often Should Maintenance Be Performed?
| Maintenance Task | Suggested Frequency |
|---|---|
| Visual Inspection | Monthly |
| Functional Testing | Quarterly |
| Electrical Safety Checks | Annually |
| Battery Review/Replacement | Every 18–24 months |
| Firmware/Software Updates | As released (quarterly ideal) |
| Calibration (if applicable) | Every 6–12 months |
| Record Audit and Validation | Annually |
Adjust based on environmental severity (e.g., extreme temperatures, corrosive chemicals, moisture).
Who Should Perform IS Device Maintenance?
Maintenance must be performed by:
Trained Personnel: Certified in hazardous area electrical safety.
Authorized Technicians: Approved by your internal safety officer or OEM service provider.
Properly Equipped Teams: Using ESD-safe tools, explosion-proof lighting, and appropriate PPE.
Unqualified repairs or inspections can invalidate ATEX/IECEx certifications, putting your site at risk.
Best Practices for Optimizing Maintenance
Implement a digital CMMS to automate schedules, alerts, and documentation.
Tag devices with RFID/barcodes to track service history.
Train field teams annually on IS safety, device handling, and compliance rules.
Centralize spare parts and use only certified replacements from OEMs.
Conduct mock audits to ensure your documentation and maintenance logs are inspection-ready.
Recommended Intrinsically Safe Devices with Easy Maintenance
Available at the Intrinsically Safe Store, the following devices are built for easy inspection, secure updates, and field reliability:
| Device | Certifications | Notable Features |
|---|---|---|
| Tab-Ex® 04 Pro DZ2 | ATEX Zone 2, IECEx | Android 13, Samsung DeX, 5G, rugged design |
| i.safe MOBILE IS930.1 | ATEX Zone 1, IECEx | IP68, glove mode, long battery life |
| Getac F110-EX | ATEX Zone 2, MIL-STD-810H | Dual hot-swappable batteries, Windows 11 |
| Aegex 100M | ATEX Zone 1, UL913 | Lightweight, field-ready, Windows-compatible |
Each is compatible with modern MDM platforms and designed for field-serviceable updates.
Conclusion
Maintaining your IS devices isn’t a matter of convenience—it’s an operational necessity. Using this intrinsically safe device maintenance checklist, organizations can ensure compliance, extend equipment life, and reduce the risks of working in hazardous environments.
Routine maintenance aligned with industry standards like IEC 60079 builds trust in your safety systems and supports long-term cost savings. Prevention is always cheaper—and safer—than reaction.
Looking for tools and spare parts? Find certified accessories and service kits.
FAQs
Can I perform maintenance on my IS devices without voiding the warranty?
Only if performed by authorized personnel using certified parts and processes. Always consult the manufacturer’s guidelines.
What tools are safe for maintaining IS equipment in hazardous zones?
Tools must be non-sparking and compliant with zone-specific safety ratings. Use certified intrinsically safe tools when required.
How do I know if an IS device is due for maintenance?
Use CMMS alerts, QR/barcode systems, or refer to manufacturer-supplied maintenance intervals. Devices often include built-in service reminders.
Can firmware updates affect my device’s IS certification?
Yes. Always ensure updates are released by the manufacturer and retain certification validity.
Where can I buy certified spare parts for IS devices?
Purchase directly from the OEM or from trusted distributors like Intrinsically Safe Store. Avoid third-party parts unless explicitly certified.
