As battery-powered technologies continue to transform industries, they are also becoming increasingly common in equipment designed for use in hazardous areas. From portable gas detectors and wireless sensors to communication devices and monitoring systems, batteries are enabling greater mobility and functionality than ever before.
However, batteries also present one of the most significant challenges when designing intrinsically safe equipment. Unlike many other electrical components, they store substantial amounts of energy and, under certain conditions, have the potential to become an ignition source. IEC 60079-11 helps manufacturers address these risks by defining requirements for equipment protected by intrinsic safety.
When developing battery-powered equipment, there are five key considerations manufacturers should keep in mind.
1. Battery selection matters
Not all battery chemistries behave in the same way. Characteristics such as energy density, internal resistance and thermal behaviour can all influence how a battery performs under both normal operation and fault conditions. Selecting an appropriate battery technology early in the design process can help minimise development challenges later.
2. Consider the complete system, not just the battery
Battery safety cannot be assessed in isolation. Protective circuitry, charging arrangements, electrical interfaces and the surrounding equipment all influence the overall intrinsic safety of the product. Understanding how these elements interact is essential when demonstrating compliance.
3. Prepare for foreseeable fault conditions
Intrinsic safety is based on ensuring equipment remains safe even when faults occur. Manufacturers should consider scenarios such as short circuits, component failures and abnormal operating conditions early in development, rather than waiting until formal compliance testing begins.
4. Design for compliance from the outset
Battery-related design changes introduced late in a project can have significant consequences for cost and programme timelines. Incorporating intrinsic safety considerations during concept development can reduce redesign, improve efficiency and help avoid delays during product approval.
When using lithium battery technology, IEC 60079-11 is not the only standard to consider. While IEC 60079-11 governs intrinsic safety, including under fault conditions, it relies on the underlying cell being fundamentally stable. Depending on the target market, baseline cell-level safety certifications to UL 1642 (for North America) and IEC 62133-2 (globally) are typically required to validate core chemical and mechanical stability. Furthermore, regardless of the explosive atmosphere certification, UN 38.3 testing is legally mandatory for all lithium battery types to permit commercial transport and air freight.
5. Work with experienced technical specialists
Battery technologies continue to evolve rapidly, bringing new opportunities alongside new engineering challenges. Working with specialists who understand both battery behaviour and intrinsic safety requirements can help manufacturers interpret technical requirements, identify potential issues early and build confidence throughout the development process.
As demand for battery-powered equipment in hazardous locations continues to grow, intrinsic safety remains a critical design consideration rather than a final compliance exercise. By considering battery selection, system design and foreseeable fault conditions from the beginning of a project, manufacturers can reduce technical risk, streamline development and support a smoother route to certification.
Ultimately, successful battery testing is not simply about demonstrating compliance with a standard. It is about ensuring products can operate safely and reliably in some of the world's most demanding environments.
Adrian Smart, Senior Consultant Engineer, Hazardous Locations at Intertek
Learn more about Intertek’s battery testing and certification services at https://www.intertek.com/batteries/
