How Do You Safely Extend Wireless Networks into Hazardous Areas?

Ex-certified wireless enclosure systems enable you to extend your existing network into hazardous areas, helping maximize the value of your current infrastructure while accelerating digitalization across the site. 

That’s exactly what our iWAP107 and iWAPXN3 wireless enclosure systems are designed to do. Solutions designed specifically for wireless with fully certified explosion protection.   

In this article, we’ll explore how these systems are designed, why there are two enclosure options in our iWAP range, and how simple, practical design principles help deliver flexible wireless connectivity in hazardous areas. 

Why Do Hazardous Areas Need Wireless Enclosures?

Most sites already have strong wireless networks in their safe areas, usually using one chosen vendor or technology to run several applications securely. When digitalization projects expand into areas where potential for an explosion is present, site teams must ensure the final solution is certified to the required levels for the area of their site in question. Often IT teams would like to maintain the standard infrastructure they already use in the safe area or at least the same wireless vendor. Typically speaking, that means IT teams must look for enclosure solutions that allow them to take non-Ex wireless devices into their hazardous areas to support the intended use case. The goal usually isn’t to redesign the network. It’s to extend what already works and maintain security and stability throughout the entire network. 

 Ex-certified wireless enclosure systems allow you to: 

• Use standard, safe-area wireless hardware in locations where the potential for an explosion is present continuously or under fault conditions. 
• Maintain a consistent network across the entire site for security and stability reasons.  
• Support digital transformation without being locked into the limited range of Ex certified wireless devices available on the market.  

Both the iWAP107 and iWAPXN3 wireless enclosure systems are built around these principles to specifically support wireless networks. A HAZLOC wireless solution to support the full life cycle of your wireless network, not just a box.  

Zone 1 and Zone 2: What’s the Difference?

What Is a Zone 1 Area?

A Zone 1 area is one where an explosive gas atmosphere is likely to occur during normal operation. 

These environments demand a robust protection concept to handle more demanding operating conditions. This is where the iWAP107 Wireless Enclosure System is used.
 Certified for Zone 1 / Zone 21, the iWAP107 enables safe and reliable wireless connectivity in these higher-risk areas. 

Equivalent classifications: 

• ATEX & IECEx: Zone 1 (gas), Zone 21 (dust) 
• US & Canada (MET): Class I, Division 1 (gas), Class II, Division 1 (dust) 

What Is a Zone 2 Area?

A Zone 2 area is one where an explosive atmosphere is not expected during normal operation, and if it does occur, it is only present for a short time. 

While these areas are lower risk, they still require appropriate protection. Their operating conditions align well with the XN3 Wireless Enclosure System.
 The iWAPXN3, certified for Zone 2 / Zone 22, provides a cost-effective way to extend wireless connectivity into these environments. 

Equivalent classifications: 

• ATEX & IECEx: Zone 2 (gas), Zone 22 (dust)
• US & Canada (MET): Class I, Division 2 (gas), Class II, Division 2 (dust)

Two Protection Approaches for two different levels of hazardous area: How iWAP107 and iWAPXN3 Keep Wireless Safe 

To keep wireless equipment safe in hazardous areas, different protection methods are available depending on what it is you are trying to certify. For our iWAP107 and iWAPXN3 wireless enclosures, we use two different protection concepts to support the intended level of certification we designed the solutions for.  

iWAP107 and Ex d (Flameproof Protection) 

The iWAP107 uses flameproof protection or Ex d, which is designed to safely contain any ignition that could occur inside the enclosure. The design on an Ex d enclosure is not meant to be airtight. Instead, it is designed to quench the flame before it reaches the outside atmosphere if an ignition situation were to occur as a result of the device inside the Ex d enclosure.  

In practice, this means:

• If ignition happens within the enclosure, it’s fully contained 
• Flame paths cool any escaping gases so they can’t ignite the surrounding atmosphere 
• The enclosure is built to perform in tougher hazardous area conditions, such as Zone 1 and Division 1 areas. 

Our iWAP107 comes in various sizes and materials, but all using the Ex d concept, where explosive atmospheres may be present during normal operation. 

If you’d like to explore this form of protection in more detail, this article provides a clear explanation: What is an Ex d enclosure?

iWAPXN3 and Ex nR (Restricted Breathing Protection)

Instead of containing an explosion, the enclosure is designed to remove the possibility if  flammable gases entering the enclosure altogether. If gas can’t get inside, there’s nothing to ignite. Enclosures following the Ex Nr protection concept can use various methods to achieve this, but typically this is done by heavily sealing the enclosure in some form.  

The result is:

• A lighter enclosure is often possible as designs do not require thick walls to accommodate flamepaths as seen in Ex d enclosures.  
• A streamlined enclosure design well suited to Zone 2 operating conditions. 

Our iWAPXN3 uses this concept and is made from aluminium using an extruded design, meaning out solution also has the capability to be varying sizes whilst maintaining the EX Nr concept under the same global certificates. This means more flexibility for the customer and installer.

You can read more about this type of protection here: What is an Ex nR enclosure?

Important Design Considerations for Hazardous Area Wireless 

Certification is an essential starting point for hazardous area connectivity, with real-world installation conditions influencing wireless enclosure design and selection. 

Environmental Exposure

Many hazardous areas are outdoors or exposed. Offshore platforms, coastal plants, and refineries face salt spray, humidity, and corrosion every day. 

Over time, these conditions can degrade enclosures that aren’t designed with the environment in mind. That’s why material selection, coatings, and sealing strategies play such a big role in long-term reliability. 

This is covered in more detail in Designing Ex wireless enclosures for high-salt environments.

Heat and Sunlight

Wireless equipment generates heat, and when installed outdoors, direct sunlight can push internal temperatures even higher. 

In hot regions like the Middle East, Africa, and Asia-Pacific, using solar isn’t just about compliance; it directly affects performance and lifespan. 

Our 5 effects of solar insolation to consider when installing hazardous area wireless technology article explains why this matters.

Antennas and Coverage

Efficient wireless performance must also factor in antenna choice and placement to ensure reliable communication with connected devices in hazardous areas. Both iWAP107 and iWAPXN3 are designed to work with standard antennas treated as simple apparatus, giving installers the freedom to optimize radio frequency (RF) coverage without adding unnecessary certification complexity.  

Our practice guide to antenna selection explores this in more detail.

Sites evolve. Networks expand. Technology changes.

As operational needs shift and digital initiatives grow, enclosure systems need to support change without creating unnecessary complexity. That’s why our wireless enclosure systems are designed to be: 

• Straightforward to install, reducing time and effort during deployment 
• Easy to maintain, helping keep ongoing intervention to a minimum 
• Flexible enough to accommodate future upgrades, allowing new technologies to be introduced as requirements evolve. 

This design philosophy is explored further in our 6 design considerations for Ex Certified Wireless Enclosure Systems blog article.

Keeping Hazardous Areas Connected

Hazardous areas shouldn’t be digital blind spots. Whether you’re enabling mobile working, supporting worker safety systems, or extending industrial connectivity from an existing network, the iWAP107 and iWAPXN3 wireless enclosures help ensure hazardous areas remain part of the wider digital ecosystem. This is especially important when you consider a lot of critical processing equipment is entirely or partially located in defined hazardous areas. Deploying sensors or personnel to access critical information in these areas requires a well-connected network to backhaul the data packages.  

If you’re looking to extend wireless connectivity into hazardous areas, the best place to start is our online configurator, where you can build a system around your site requirements. 

Try Now: Wireless Enclosure Configurator 

About the Author

JP

Julian Poyner

Head of Engineering

From a highly technical background, Julian delivers strategic leadership to our Engineering and R&D departments. With a significant patent portfolio, Julian brings a pedigree of innovation to the development of our market leading products.

Last updated on February 4, 2026

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