ATEX Zone 2, Portable WiFi Extender Units

The objective was to create a compliant, self-sustaining power and communication system suitable for hazardous-area use in the European market.  Delivery timeframes, cost control, and product certification were defined as critical success factors.

The new solution would be targeted for installation at sites in Wales and the Netherlands.

Solution

The product designed by JCE, uses renewable energy to supply continuous power to a WiFi/5G repeater mounted on the telescopic mast, which allow the units to link together to form a long range, secure site network.

These systems support applications such as remote connectivity and the sitewide secure RFID (Radio Frequency Identification) program. Employees’ RFID tags connect automatically to the network, allowing operations and safety teams to see the real time location and identity of all personnel throughout the facility. This capability greatly enhances site safety — for example, during a fire or emergency, responders can immediately identify who is in each area and whether anyone is missing.

To support safe handling, transport, and on-site deployment, the solar cabinets were supplied with three custom engineered transport trailers. Each trailer was designed with integrated forklift forks, dimensioned to interface precisely with the cabinet’s certified forklift pockets to ensure secure engagement during lifting and loading. Once positioned, the cabinets are mechanically restrained within the trailer using designated locking points and tiedown features, maintaining stability during transit and mitigating vibration or movement.

This configuration enables the cabinets to be loaded, transported, and offloaded directly from the trailer without reliance on external lifting equipment such as cranes, thereby streamlining logistics, reducing mobilisation costs, and improving operational safety — particularly in remote locations where lifting infrastructure may be limited.

All components are suitable for ATEX Zone 2 hazardous environments, ensuring full compliance with safety standards.

The standard system is housed within a galvanized steel cabinet, containing the Ex d Solar Charge Controller, Ex d Battery Isolator, Ex e Batteries, and a manual winch that operates a 6-meter telescopic mast. An Ex wireless unit is mounted on the mast, which extends from the centre of the stainless steel enclosure when operated, with the enclosure lid opening and closing automatically. To ensure security and prevent misuse, the housing is fully lockable.

Externally, the housing incorporates three foldable Ex e solar panels, which can be adjusted to optimise energy capture. For stability, the enclosure is equipped with ground securing stabilising feet, ensuring safe and reliable operation in the field.

The final design shifted from the initial concept:

• More robust cabinets were used.
• Higher tier trailers were supplied.
• An additional battery isolator was added due to space limitations in the charge controller.
• The battery system was split into two 12VDC enclosures instead of one 24VDC, to optimise efficient weight distribution.
• Solar supports and bracketry were designed and fabricated with operator installation in mind. The supports were fixed onto specially designed brackets which allow a single operator to easily extend the solar panels and fix into deployment position.
• JCE fabricated new mast brackets when the supplier’s design proved unsuitable.

Outcome