In environments where explosive atmospheres are a daily reality—chemical plants, oil refineries, mining operations, and manufacturing—intrinsically safe equipment plays a critical role in ensuring the safety of personnel and operations. But owning the right devices is only part of the equation. Maintaining them properly is just as crucial.
Neglecting best practices for intrinsically safe maintenance can lead to equipment failure, safety violations, or even hazardous incidents. Worse, improper maintenance may void your ATEX or IECEx certifications, leaving your operations exposed to regulatory penalties or shutdowns.
This guide will help you avoid the most common maintenance mistakes, understand proper care routines, and implement systems that extend the life and reliability of your certified equipment.
Learn how to extend the life of your ATEX-certified equipment → Maintenance Essentials Guide
Why Intrinsically Safe Equipment Requires Special Maintenance
Unlike standard electronics, intrinsically safe devices are engineered to prevent sparks, high heat, or any energy that could ignite flammable gases or dust. They feature sealed enclosures, temperature controls, anti-static surfaces, and certified batteries or components. Even a minor deviation—such as replacing a battery with a non-approved unit—can compromise safety.
That’s why routine inspections and proper maintenance are not optional. They’re essential to keep these devices functioning within their original safety parameters.
What Are the Most Common Intrinsically Safe Maintenance Mistakes?
Let’s explore the key maintenance errors that operators, technicians, or procurement teams often make—and how to avoid them.
Using Non-Certified Replacement Parts
One of the most dangerous mistakes is swapping certified components (like batteries or screens) with generic, non-approved parts. This immediately voids certification and exposes the device to potential ignition risks.
Always use OEM-approved accessories and replacements specifically designed for your device’s ATEX/IECEx rating.
Overlooking Regular Inspection Protocols
Routine inspections are critical for spotting wear and tear. Without a preventive maintenance checklist, it’s easy to miss:
Cracked casings
Worn seals or gaskets
Display degradation
Battery swelling
Neglecting these signs can lead to field failures—or worse, safety hazards.
Improper Charging Practices
Charging a device in a hazardous zone with a non-rated charger or using a faulty port is a serious violation. Always ensure that:
You use Zone-certified charging equipment.
Charging occurs outside hazardous areas, if not rated for Zone use.
Ports and connections are clean and undamaged.
Ignoring Firmware and Software Updates
Outdated software may seem harmless, but for intrinsically safe mobile devices or tablets, it can:
Affect device performance
Introduce compatibility issues
Disrupt manufacturer compliance with safety protocols
Check manufacturer guidelines for approved update procedures that preserve certification status.
Cleaning with Incorrect Materials
Harsh solvents or abrasive tools can damage anti-static coatings, seals, or display screens—especially in rugged devices like explosion-proof tablets or cameras.
Always clean with:
Non-conductive, anti-static cloths
Approved screen cleaners
Soft brushes designed for industrial electronics
How Often Should You Perform Intrinsically Safe Maintenance?
The frequency of intrinsically safe maintenance varies depending on device type, environment, and zone classification. Here’s a general guideline:
| Maintenance Task | Recommended Frequency |
|---|---|
| Visual Inspection | Before each shift or weekly |
| Functional Testing | Monthly or after exposure to damage |
| Software/Firmware Checks | Quarterly or per manufacturer updates |
| Battery & Port Condition | Monthly or before long deployments |
| Annual Certification Review | Annually, especially for Zone 0 devices |
Documenting each maintenance activity ensures you’re ready for safety audits and warranty claims.
Browse certified intrinsically safe devices engineered for hazardous areas → Explore Devices
Can Improper Maintenance Void ATEX or IECEx Certification?
Yes—and it happens more often than people realize.
ATEX and IECEx certifications are valid only under the condition that devices remain unmodified and are maintained using approved procedures and components. If you:
Replace a certified battery with a generic one
Crack a seal and continue use without inspection
Apply software not verified by the manufacturer
…you could lose certification immediately. This can also invalidate insurance coverage or trigger regulatory violations during audits.
To stay compliant:
Keep a maintenance log (digital or physical)
Record serial numbers, parts used, and inspections
Use approved repair centers or manufacturer support
Best Practices for Intrinsically Safe Maintenance Programs
Maintain a Digital Maintenance Log
A digital record of maintenance activities is invaluable for compliance and equipment lifecycle planning. Use rugged tablets like the i.safe MOBILE IS930.1, which are designed for hazardous zones and can be integrated into mobile asset management systems.
Train Technicians on Hazardous Area Safety
Field technicians must be trained in:
Zone 0/1/2 classification differences
Handling explosion-proof hardware
Recognizing damage that compromises certification
Inadequate training often leads to accidental misuse or mishandling of devices.
Use Only Certified Tools and Accessories
Don’t allow workers to use uncertified screwdrivers, chargers, or accessories near hazardous devices. Only use:
ATEX/IECEx rated chargers
Anti-static toolkits
Certified cleaning and handling gear
The Intrinsically Safe Store offers a full range of accessories and tools to meet these standards.
Still have questions? Talk to an expert about compliant maintenance practices → Contact Us
FAQs – Intrinsically Safe Maintenance Questions Answered
What happens if I replace a certified battery with a generic one?
It voids the device’s certification, which could make it illegal to use in a hazardous area.
Can I use alcohol wipes to clean my intrinsically safe device?
Only if approved by the manufacturer. Some chemicals can degrade sealants or conductive coatings.
Do I need to log every maintenance activity?
Yes. Proper logging protects you during audits and supports your warranty and compliance obligations.
Are maintenance needs different for Zone 0 devices?
Absolutely. Zone 0 equipment demands more frequent checks and stricter component handling due to continuous exposure to explosive atmospheres.
Are software updates considered maintenance?
Yes, particularly for smartphones and tablets. However, only perform updates that are validated and documented by the device manufacturer.
Product Showcase – Certified Devices with Maintenance-Friendly Design
Here are top intrinsically safe products built for durability and long-term maintenance ease, available from Intrinsically Safe Store:
| Product | Certifications | Maintenance Features | Device Type |
|---|---|---|---|
| Ecom Smart-Ex 02 DZ1 | ATEX Zone 1, IECEx | Field-replaceable battery, OTA firmware | Rugged Smartphone |
| i.safe MOBILE IS930.1 | ATEX Zone 1, IECEx | IP68 rated, corrosion-resistant casing | Industrial Android Tablet |
| Bartec Pixavi Cam | ATEX Zone 1, IECEx | Replaceable lens glass, easy disassembly | Explosion-Proof Camera |
| GfG Micro IV Gas Detector | ATEX Zone 0, IECEx | Modular sensor head, maintenance alert system | Personal Gas Detector |
Best For:
Field Teams: Ecom Smart-Ex 02 for mobile data capture and voice communication
Inspections & Maintenance Logs: IS930.1 for logging procedures in harsh zones
Visual Auditing: Pixavi Cam for clear, safe image capture in explosive atmospheres
Air Quality Monitoring: GfG Micro IV for real-time gas readings and alerts
Conclusion: Maintenance Is Mission-Critical
The safety and performance of your intrinsically safe equipment depend on more than just proper certification—they depend on how you care for it. Neglecting inspections, using non-approved parts, or skipping software updates can compromise your team’s safety and your operation’s compliance status.
By following best practices in intrinsically safe maintenance, you’ll extend the life of your devices, avoid costly repairs, and protect your crew in even the most hazardous work zones.
