HydITEx transforms the existing unidirectional PoE Ethernet system into a smarter, explosion-proof bidirectional architecture. Four key features considered critical to this implementation are the ability to communicate, control the flow of energy between different energy processing structures in the system, short-term energy storage, and bidirectional transmission of energy packets using short, small pulses (50 µJ energy pulses) over a single Ethernet cable.

Ex Dep IEMS Ethernet is a technology that allows network devices to be powered over the same Ex Ethernet cable that carries data. Ex Dep IEMS Ethernet integration with Ex Ethernet UTP 1000 1Gigabit and Ex Ethernet STP 10G 10Gigabit. This eliminates the need for separate power cables and power sources, simplifying installations. Explosion-proof digital electrical power Ex Dep IEMS Ethernet uses standard structured copper Ethernet (for example F/UTP CAT5, STP CAT7) cabling and Class 2 low-voltage wiring techniques. Ex Dep IEMS Ethernet safely transmits up to 1000 W of power over a distance of 100 m (for hydrogen).

Explosion-proof Ex Dep IEMS Ethernet digital electric power delivers both digital data via Ethernet and electrical power in a single hybrid cabling infrastructure, making installation much easier and more cost-effective than traditional 110/220 AC or 24 V DC electrical systems. This technology allows power to be taken much longer distances with lower voltage drops – and without dealing with large copper wires.

Ex Dep IEMS Ethernet The transmitter takes normal electricity and modulates it into small pulses or 50 µJ energy bursts over cop per Ethernet cabling. Each packet contains only a very small amount of energy, less than what is needed to ignite an explosive atmosphere (IIC and hydrogen), so individually they are not dangerous.

Each packet is sent to an Ex Dep IEMS Ethernet receiver from an Ex Dep IEMS Ethernet transmitter, which contains local embedded processing. Each power packet is analyzed using a digital signal processing engine to determine that power is distributed accurately and safely from transmitter to receiver. If a fault is detected, the next energy packet is not sent. As long as the electricity stays within the intended circuit and flows in the correct path, it does not cause explosion-proof problems. This protects against high current levels, ground fault, arc fault and touching hazards. The receiver converts the energy packets back to analog DC to supply local loads or to return energy within the electrical grid. Supercapacitors with different high capacitance values ​​are used to efficiently store and quickly release energy, which expands the application possibilities of IEMS.

The data transmission subsystem interacts with the host system via an Ethernet communication channel. All communication is carried out transparently to the host.

• The Ex Dep IEMS Ethernet system is highly efficient, low noise, and requires little electromagnetic filtering to meet EMI standards.

• Bidirectional transmission of energy. Possibility of returning regenerative energy to the general power grid or from local storage batteries to the general power grid.

• Short-Term Energy Storage. This allows us to smooth out peak loads, balance the load, and eliminate short-term power outages.

• Simplified and more economical installation. Energy delivery is carried out similarly to PoE. Installation does not require the services of an electrician. Instead, you can leave the installation to system integrators.

• Effective backup operation to Traditional Power Sources.

• Provides backup operation in case of emergency limited power supply.

• Gves electric power for network device in low-power mode.

• Remotely provides the power needed to wake up the device via WoL.

• Supports WoL, an industry standard that allows a computer to be turned on or woken up from a low-power state using a network message.

• The availability of a special version for functional safety level PL e according to ISO 13849-1 (SIL 3 according to IEC 62061) underlines its suitability for critical applications where functional safety is of paramount importance.

• Allows you to work even with a partially damaged cable in an economical backup or emergency mode.

• Data Backbone for Intelligence: 10 Gigabit Ethernet provides the high-speed, ultra-low-latency network backbone essential for transporting the massive volumes of real-time data generated by modern industrial processes, sensors, and the Industrial Internet of Things (IIoT). 

* WoL is an Ethernet networking standard that allows a properly configured network device to be turned on or awakened by a network message. The Wake-on-LAN (WoL) command is transmitted using the UDP protocol, typically on ports 7 or 9. The WoL packet, also known as the "magic" packet, contains the MAC address of the target device. This packet does not use an IP address because the computer is turned off and does not have a network driver. The main part of the "magic" package is 6 repetitions of the 0xFF character, followed by 16 repetitions of the target computer's MAC address. Thus, even when the computer is turned off, it can receive and process network packets to "wake up" when a specific signal is received.

Explosion-proof digital electrical power Ex Dep IEMS Ethernet project is under development

Why do you need Explosion-Proof digital electrical power 

Ex Dep IEMS Ethernet 1000W 10 Gigabit ?

Executive Summary

Operating in hazardous industrial environments presents complex challenges, primarily the critical imperative of preventing explosions while simultaneously striving for operational efficiency and technological advancement. This report examines the profound necessity and synergistic benefits of integrating explosion-proof digital electrical power, Industrial Energy Management Systems (IEMS), and 10 Gigabit Ethernet. This integrated approach is not merely a collection of disparate technologies but a cohesive solution that fundamentally enhances safety, optimizes operational intelligence, ensures data integrity, and future-proofs industrial infrastructure for the demands of Industry 5.0. By addressing the inherent risks of explosive atmospheres with certified equipment, leveraging advanced digital power distribution, establishing a high-speed data backbone, and implementing intelligent energy management, organizations can achieve a new paradigm of safe, efficient, and resilient operations.

The Evolution to Digital Electrical Power

Digital power supplies represent a significant advancement over traditional analog designs. Unlike analog systems that rely on fixed analog circuitry, digital power supplies employ microcontrollers or Digital Signal Processors (DSPs) to regulate voltage and current. This fundamental shift allows power conversion and regulation parameters to be adjusted dynamically through software, offering unmatched precision and adaptability.

The benefits of digital power supplies compared to their analog counterparts stem primarily from their advanced use of digital control and enhanced communication capabilities.   

• Precision and Flexibility: Digital power supplies provide highly accurate control over output voltage and current. Their parameters can be adjusted dynamically, enabling real-time optimization and customization for specific application needs.

• Efficiency: Enhanced control algorithms and adaptive techniques inherent in digital designs lead to improved energy efficiency, significantly reducing energy loss and heat generation.   

• Communication and Monitoring: A key advantage is the integration of communication interfaces, which enable remote monitoring and control. This facilitates real-time diagnostics, data logging, and proactive system management and maintenance.   

• Programmability: Digital power supplies can be programmed to handle multiple output profiles and conditions, offering greater versatility for diverse applications.   

• Adaptive Control: They possess the capability to adapt dynamically to changing load conditions, ensuring optimized performance under varying operational demands.   

• Software Updates: Functionality enhancements or issue corrections can be implemented through firmware updates, eliminating the need for costly and disruptive hardware modifications.   

• Integration and Miniaturization: By integrating control functions into a single chip, digital designs reduce component count and PCB space, leading to more compact and efficient power solutions.

The concept and mechanism of digital electrical power

This innovative technology enables transmission of significant power over long distances by segmenting energy into hundreds of thousands of small packets per second. The Ex System Dep IEMS Ethernet illustrates this by transmitting power packets with short, low-energy pulses, typically 50 µJ energy bursts, over standard copper Ethernet cable. This extremely low energy content in each packet is a critical factor in preventing fires in explosive environments. At its core, it is a form of fault management system (FMPS) adapted for hazardous areas. The operating mechanism includes a transmitter that converts normal analog electricity into these digital, intrinsically safe energy packets. These packets are then sent to a receiver that contains local, built-in processing capabilities. The receiver continuously analyzes each incoming packet. If any fault condition is detected - such as touching a live wire, a short circuit, or even a water leak - the system instantly stops transmitting the next energy packet. Immediately stopping the power supply is fundamental to its safety.

Internal safety functions and fault management

The defining characteristic is its set of inherent safety functions, primarily focused on sophisticated fault management.

The most important safety feature is the instantaneous fault detection and shutdown capability. The system can detect unusual conditions or faults, such as increased power losses during transmission, insulation damage, or water in the cable, and will shut down the transmission within microseconds. This ultra-fast response prevents electrical shock, eliminates the risk of ignition and subsequent explosion or fire.

A key aspect of its safety is its compliance with the principles of intrinsic safety through packaging. Each energy packet transmitted contains an extremely small amount of energy, often as little as 50 µJ . This energy level is well below the minimum required to ignite even highly sensitive explosive atmospheres such as those containing hydrogen (classified as gas group IIC). This design ensures that individually these packets do not pose a hazard, effectively confining the energy at the source, which is the cornerstone of intrinsic safety . In addition, the system provides reliable protection against common electrical hazards including high current levels, ground faults, arc faults and direct contact hazards.

Traditional explosion protection methods, such as flameproof enclosures (Ex d), are designed to contain an explosion if it occurs inside. Intrinsically safe systems (Ex i) limit energy to prevent combustion under all conditions, including fault conditions. FMPS takes this concept further by actively monitoring and managing power flows in real time, instantly disconnecting power when a fault is detected. This represents a fundamental shift from passive protection to a proactive, dynamic safety mechanism. Ex Packet Power Supply Dep IEMS Ethernet with fault management offers a fundamentally safer approach by preventing dangerous energy releases before they can become a source of ignition. This capability represents a significant advance over purely passive explosion protection methods, ensuring a higher level of safety in unstable environments.

Operational advantages in dangerous Wednesdays

Implementation of digital power industry Ex Dep IEMS Ethernet in hazardous environments provides many operational benefits that go beyond simply meeting safety requirements and directly impact efficiency and cost effectiveness.

One of the most significant benefits is simplified installation and reduced cabling requirements. By transmitting both digital data and intrinsically safe power over a single hybrid Ethernet cable (e.g. Cat 5, Cat 7), Ex Dep IEMS Ethernet eliminates the need for separate power cables and power supplies. This greatly simplifies installation processes and reduces overall cabling infrastructure, drawing parallels with Power over Ethernet (PoE), but with its own safety features, adapted for hazardous areas. 

In addition, digital electricity allows for greater distances for power delivery. Unlike traditional AC or 24V DC electrical systems, it can transmit power over much greater distances with minimal voltage drop and without the need for large, expensive copper wires. This capability is especially useful for large, dispersed industrial facilities where power must be distributed over vast areas.  

The inherent security of the system also results in significant cost efficiencies. Simplified installation, reduced material costs for cabling, and the ability to use low-voltage wiring (due to the inherent security of the system) result in significant savings in capital and operating costs. In some cases, the installation process may not even require the services of a licensed electrician, allowing qualified system integrators to handle the deployment, further reducing labor costs.  

In addition, Ex systems Dep IEMS Ethernet offers increased flexibility and scalability. The technology can power devices with different load requirements and makes it easy to expand the network, as new devices can be added without the need for additional power outlets. This flexibility means that power distribution can be reconfigured with minimal disruption to adapt to changing operational needs.  

Historically, achieving high safety standards in hazardous areas has often entailed increased complexity, higher costs and reduced operational flexibility, exemplified by requirements for heavy piping, specialist electrical contractors and limitations on electrical transmission distances. Ex Dep IEMS Ethernet directly addresses this problem by making power delivery inherently more secure through packetization and active fault management, while offering significant operational efficiencies such as simplified pad cables, more long distances transmissions and more low cost on installation. This is rapprochement has decisive meaning for satisfaction needs modern industrial operations where safety and efficiency have paramount meaning . This is unique combination allows change paradigm where increased safety V dangerous zones more Not requires compromise between operational efficiency and economic w incapacity, thereby paving the way for more flexible and cost-effective industrial deployments.

Operational advantages:

• Packetized Energy Transfer. Energy is divided into hundreds of individual packets (e.g. 50 µJ pulses) and applied thousands of times per second. The energy in each packet is too small to ignite an explosive atmosphere, even for highly flammable substances such as hydrogen (gas group IIC), providing inherent intrinsic safety. Related standards/ratings - UL Class 4, IIC/Hydrogen Compatible.

• Instantaneous fault shutdown. A digital pilot signal continuously monitors the line; if any unusual condition or fault is detected (e.g. short circuit, live wire touched, water leak), power flow is immediately stopped (within microseconds). Prevents electrical shock, fire and equipment damage by actively de-energizing the circuit before a hazardous situation can escalate, moving from reactive to proactive safety. Relevant Standards/Ratings - UL Class 4, NEC Acceptance.

• Higher power delivery. Can transmit significant power over small cables, delivering hundreds to thousands of watts of power. Allows power to be transmitted over much longer distances (e.g. 100 m for hydrogen applications) with lower voltage drop, reducing the need for thick copper wires and intermediate power supplies in growing industrial plants. Relevant standards/ratings - UL Class 4, up to 1000 watts at 100 m (for hydrogen)

• One Cable for Power and Data. Delivers both digital data (Ethernet) and power over a single Ethernet hybrid copper cable (e.g. F/UTP CAT5, STP CAT7). Simplifies installation, significantly reduces cabling and labor costs, and eliminates the need for separate power and data infrastructure, making deployment more cost-effective and less complex. Related Standards/Ratings - Standard Structured Copper Ethernet Cabling System, Class 2 Low-Voltage Wiring Practices.

• Low voltage wiring practice. Despite the higher power, the inherent safety features of the devices allow the use of low voltage wiring. Reduces installation costs since specialized electricians are not required, allowing system integrators to handle deployment.

Compliance and Certification for Digital Electricity

The implementation of digital electricity, in particular fault management systems (FMPS), is largely driven by its compliance with established and new safety and certification standards.

A significant indicator of FMPS acceptance in the industry is the adoption of a new section in the National Electrical Code (NEC) specifically dedicated to this technology. Crucially, it has been UL Class 4 approved. This rating demonstrates the system’s ability to prevent catastrophic events by immediately shutting off power when a fault is detected, thereby protecting personnel and property.

The underlying principle of limiting energy to intrinsically safe levels, such as the 50 µJ energy bursts described for Ex systems Dep IEMS Ethernet - means that these systems are designed from the ground up to meet the essential intrinsic safety ( Ex i) requirements defined by international standards such as IECEx and ATEX.

The recent inclusion of FMPS in the NEC marks a critical stage in its maturation and widespread acceptance. It is not just a technology being developed in isolation; it is a technology that actively influences and is improved by safety standards.

Innovation drives the development of new safety standards, and the establishment of these standards in turn enables wider adoption and deployment of innovative technologies with regulatory certainty. Therefore, formal recognition and standardization of such systems is necessary for their widespread adoption in safety-critical hazardous environments, building confidence among industrial users.

The Role of IEMS in Optimizing and Improving Energy Efficiency 

IEMS plays a key role in optimizing energy consumption and improving the efficiency of industrial operations with its advanced capabilities.

The core function of IEMS is its ability to provide real-time monitoring and management of energy operations. It enables continuous supervision and dynamic adjustment of energy systems. This includes providing minute-by-minute real-time data on electricity, water and gas consumption, providing detailed transparency into energy usage patterns.

Using sophisticated data analytics and forecasting capabilities, IEMS transforms raw energy data into actionable information. By analyzing information in real time, it can pinpoint areas for improvement, guide the implementation of specific energy conservation measures, and identify recurring patterns to predict future energy needs. This predictive ability extends to maintenance, enabling potential equipment issues to be identified and addressed early, thereby preventing costly downtime and extending the life of assets.

A direct consequence of optimized energy use is significant cost savings. IEMS ensures that all energy-consuming devices and systems operate at an optimal level, reducing unnecessary consumption, minimizing costly peak costs, and ultimately reducing overall operating costs.

Crucial role of IEMS for energy storage and power supply stabilization

Supercapacitors with different high capacitance values ​​are used to efficiently store and quickly release energy, which expands the application possibilities of IEMS.

Short-Term Energy Storage: While batteries excel at long-term energy storage, supercapacitors are ideal for storing and delivering energy in short, high-power bursts. This makes them valuable for:

• Peak Shaving: Quickly supplying power during periods of high demand to reduce reliance on the grid and lower peak demand charges.

• Load Leveling: Absorbing excess energy during low demand and releasing it during high demand to smooth out power fluctuations.

• Bridging Power Gaps: Providing seamless, short-term backup power during brief power outages or sudden load changes, ensuring uninterrupted operation of critical equipment within the IEMS.

Hybrid Energy Storage Systems (HESS): Supercapacitors are often combined with batteries (e.g., lithium-ion batteries) in HESS. This leverages the strengths of both technologies: batteries for high energy density and long-duration storage, and supercapacitors for high power density and rapid response to transient loads. The IEMS manages the coordinated operation of these diverse storage components.

Regenerative Braking (e.g., in industrial machinery,): In industrial equipment like cranes integrated into an IEMS, supercapacitors can capture and store energy generated during braking, which can then be reused, improving efficiency.

Fast Charging/Discharging Cycles: Supercapacitors can undergo virtually unlimited charge and discharge cycles without significant degradation, making them highly durable and reliable for applications requiring frequent power delivery.

How IEMS Leverages Capacitors:

An IEMS integrates capacitors and supercapacitors into its overall control strategy. It monitors the real-time energy demand, generation from various sources (including renewables), and grid conditions. Based on this data and advanced algorithms (AI, machine learning), the IEMS can:

• Strategically charge and discharge capacitors/supercapacitors to maintain voltage stability, regulate frequency, and optimize power flow.

• Prioritize energy sources (e.g., drawing from supercapacitors for immediate power needs, then from batteries for sustained demand, and finally from the grid).

• Manage transient events like sudden load changes or grid disturbances by rapidly deploying the stored energy in capacitors.

• Improve the overall efficiency and longevity of the entire energy system by reducing stress on other components (like batteries or generators) and minimizing energy waste.

Supercapacitors provide IEMS with the flexibility and fast response needed to achieve reliable power supply stabilization and efficient energy management, especially in dynamic and complex power systems.

Benefits of IEMS for Hazardous Environments

In hazardous industrial environments, the benefits of IEMS extend far beyond general energy optimization, directly contributing to improved safety and operational reliability.

IEMS dramatically improves safety and reliability by thoroughly analyzing detailed power quality data, identifying inefficiencies, and proactively addressing potential issues before they become hazardous conditions. This capability directly reduces the risks associated with equipment failures and power outages that could otherwise lead to hazardous situations in explosive atmospheres.

Through continuous monitoring and predictive analytics, IEMS provides a critical level of proactive hazard identification. It can detect subtle anomalies in energy consumption or equipment behavior that may indicate an impending malfunction, overheating, or other conditions that may precede a critical failure or ignition source. This early warning system enables timely intervention, preventing the development of potentially explosive situations.

Moreover, IEMS ensures optimized power distribution by dynamically adjusting power levels based on real-time demand. This ensures a stable and efficient power supply, which is essential for maintaining safe operating parameters in hazardous areas where fluctuations or uncontrolled release of power can have catastrophic consequences.

While explosion-proof equipment and digital power systems provide direct protection against fire, IEMS acts as a comprehensive “safety orchestrator.” By collecting and analyzing real-time data from all connected devices, including sensors, meters, and controllers in hazardous areas, IEMS can detect subtle deviations that may precede a critical failure. This capability goes beyond simply preventing fires from the electrical equipment itself; it actively helps prevent the very conditions that can lead to an explosion, such as localized overheating or unexpected overcurrents, by optimizing the entire energy ecosystem. This systemic oversight and predictive capability turns energy management into a proactive tool for ensuring safety and reducing risks in hazardous environments.

Data Backbone for Intelligence: 10 Gigabit Ethernet 

10 Gigabit Ethernet provides the high-speed, ultra-low-latency network backbone essential for transporting the massive volumes of real-time data generated by modern industrial processes, sensors, and the Industrial Internet of Things (IIoT). It enables the rapid, reliable communication necessary for advanced automation, real-time control systems, and the efficient operation of sophisticated analytical platforms. 

Integration with digitalization and IIoT

IEMS is a cornerstone of the broader digital transformation of industrial operations, especially in hazardous environments, through seamless integration with the Industrial Internet of Things (IIoT).

As a key component of IIoT , IEMS enables continuous data collection and analysis, from individual field devices to higher-level control systems and cloud platforms. This comprehensive data flow is essential for creating truly intelligent industrial ecosystems.

The integration of AI and ML into IEMS enables sophisticated predictive maintenance capabilities. By analyzing sensor data, these systems can identify early signs of equipment failure, enabling proactive interventions and significantly reducing unplanned downtime. This is especially valuable in hazardous areas, where manual inspections often come with risks and costs.

In addition, IEMS can integrate with smart grid applications and microgrids, enhancing overall energy resilience and ensuring continuous and reliable power supply. Such resilience is critical to maintaining critical operations and safety systems in hazardous areas.

The initial drivers for implementing hazardous area equipment are typically regulatory compliance and basic safety. However, the strategic integration of IEMS with digital power and Industrial Ethernet turns these needs into a distinct competitive advantage. By enabling real-time energy optimization, predictive maintenance, and significant reductions in operating costs, companies can achieve higher uptime, optimize asset utilization, and reduce total cost of ownership. This shift takes organizations beyond simple regulatory compliance to a state of operational excellence. Thus, the convergence of IEMS with advanced hazardous area technologies is not only about meeting safety regulations, but also about unlocking significant operational efficiencies and creating a more resilient, intelligent, and profitable industrial ecosystem.

One of the most immediate and tangible benefits is the reduction in wiring and installation costs. Ex Technology Dep IEMS Ethernet significantly reduces installation time and cabling costs, with reports indicating potential wiring cost reductions of up to 85%. Ex Dep IEMS Ethernet further enhances this benefit by combining power and data transmission over a single cable, further simplifying the infrastructure.

In addition, these integrated systems result in a significant increase in plant availability. The real-time monitoring and predictive maintenance capabilities supported by IEMS enable early identification of maintenance needs. This proactive approach helps avoid unplanned downtime, thereby significantly increasing overall plant availability and uptime.

Most importantly, the systems can improve safety performance. For example, intrinsically safe devices powered by artificial intelligence have been shown to reduce workplace accidents in chemical and oil refineries by 30% through proactive safety alerts. Homeland Security Ex Dep IEMS Ethernet, with its 50 µJ energy pulses and instant shutdown upon fault detection, directly prevents fires, acting as a primary line of defense against explosions.

While safety is often perceived as a cost center, the benefits demonstrated by these integrated systems provide a clear return on investment (ROI). Reduced installation costs, minimized downtime, increased equipment availability, and a quantitative reduction in accidents directly translate into significant savings in operating costs and increased profitability.

Synergetic integration

The real transformative potential for hazardous industrial operations comes from the synergistic integration of explosion-proof digital power supply (Ex Dep), Industrial Energy Management Systems (IEMS) and Industrial Ethernet. This convergence creates a single, intelligent and inherently safer operating framework. The integration enables the use of a single hybrid cabling infrastructure, typically copper Ethernet, to carry both digital data and intrinsically safe power (Ex Dep). This unified approach significantly simplifies deployment and significantly reduces costs compared to traditional systems that require separate power and data lines. Together, they form a comprehensive “smart safety network.” This integrated system not only prevents explosions due to individual component failures, but also proactively optimizes energy consumption and the overall operational health of the entire plant, thereby systematically reducing overall risk. The integrated system creates a comprehensive, intelligent safety and efficiency framework, where each technology leverages the benefits of the others, resulting in a reliable and sustainable operating environment in hazardous areas.

IEMS receives more accurate and complete real-time data for analysis, including not only primary process values, but also secondary parameters and critical asset health feedback. This detailed data allows for a much deeper understanding of operating conditions. This wealth of real-time data translates directly into improved control and responsiveness. IEMS can use this information to make immediate, dynamic adjustments to optimize energy consumption, regulate systems such as HVAC and lighting, and manage complex industrial processes. Such fast, accurate control is essential for maintaining safe operating parameters and responding to urgent events in hazardous conditions. In addition, end-to-end digital communications provide complete visibility into operations throughout the plant lifecycle. This provides operators and managers with a complete, real-time overview of all plant activities, enabling them to make faster, more accurate adjustments to optimize performance and reduce risk.

Traditional hazardous area operations have often relied on reactive measures and periodic manual inspections. The integration of these advanced technologies fundamentally changes this paradigm to a predictive model. When analyzed, IEMS allows for the early detection of subtle anomalies and potential failures. This capability enables proactive maintenance and targeted interventions, significantly reducing the likelihood of hazardous incidents and minimizing costly unplanned downtime. Thus, the integrated system transforms hazardous area management from a reactive, compliance-oriented activity to a proactive, data-driven approach that improves both safety and operational efficiency.

Support for Industry 4.0/5.0 and IIoT in Ex zones 

Combined capabilities of explosion-proof digital power supply, IEMS and Industrial Ethernet, in particular Ex Dep IEMS Ethernet provides the necessary infrastructure to fully implement Industry 4.0/5.0 and Industrial Internet of Things (IIoT) initiatives in hazardous environments.

This integration serves as the basis for developing sophisticated solutions for smart factories. It supports advanced applications such as real-time location systems (RTLS) for tracking personnel and assets, comprehensive asset management, and intelligent monitoring systems that provide continuous oversight of the plant’s condition.

Moreover, a reliable and secure power and communication infrastructure facilitates the deployment of advanced automation and robotics. Intrinsically safe robotics and autonomous inspection devices can be used safely to perform hazardous or routine tasks, thereby significantly reducing human exposure to hazardous areas and improving overall workplace safety.

The benefits of digitalization, including IIoT, AI, and predictive maintenance, are widely recognized. However, their implementation in hazardous areas presents unique challenges due to the inherent risks. Integrated Ex Dep IEMS Ethernet provides the “invisible infrastructure” – a secure power and communication backbone – that makes these advanced digital applications not only possible, but also inherently safe in environments where a single spark could have catastrophic consequences. Without this dedicated and compliant foundation, the promise of Industry 4.0/5.0 in hazardous sectors would remain largely unfulfilled. This integrated solution thus serves as a fundamental, safety-compliant backbone that enables digital transformation and the adoption of advanced technologies in high-risk industries. Integrated technologies contribute to a safer and more productive model of human-machine interaction, enabling industries to use advanced automation in hazardous areas while minimizing human risk.

Security integrity levels and performance levels

Safety Integrity Level (SIL) and Performance Level (PL) are comparable metrics that can be converted to each other, as they both assess the probability of a dangerous failure. Manufacturers typically provide the necessary safety characteristics to determine the appropriate SIL and PL levels for their components.

As electrical systems become increasingly digital and complex, qualitative safety assessments alone are no longer sufficient. SIL and PL provide a reliable quantitative basis for assessing the reliability and performance of safety functions. For integrated systems such as Ex Dep IEMS Ethernet, which cover both power supply and communication, these levels are crucial to demonstrating that the entire system meets the required safety performance, not just its individual components. The availability of a special version for functional safety level PL e according to ISO 13849-1 (SIL 3 according to IEC 62061) underlines its suitability for critical applications where functional safety is of paramount importance. Ex Dep IEMS Ethernet uses 4-pair twisted pair cable and uses a unique automatic crossover technology for data and power line interfaces, which automatically detects working pairs and sets up a backup configuration for data and power transmission/reception. This allows operation even with a partially damaged cable in an economical backup or emergency mode. This increases the fault tolerance of the entire efficient system and highlights its suitability for mission-critical applications.

Recommendations

Convergence of explosion-proof digital power grid (Ex Dep / Fault Managed Power Systems (IPMS), Industrial Energy Management Systems (IEMS), and Industrial Ethernet represent a profound paradigm shift in managing safety and efficiency in hazardous industrial environments. This comprehensive approach goes beyond traditional protection methods to deliver inherently safer, more efficient, and smarter operational capabilities.

The main advantages of this comprehensive solution are multifaceted:

• Unprecedented safety: Achieved by packetized, fault-controlled power supply, featuring ultra-low energy spikes (e.g. 50 µJ) and instantaneous shutdown when a fault is detected. This is complemented by intrinsically safe, high-bandwidth Ethernet communications, ensuring that sources of ignition are eliminated or localized in advance.

• Improved operational efficiency: Achieved through significantly simplified installation processes, reduced cabling requirements, increased power and data transmission range, real-time energy consumption monitoring, and AI-based predictive maintenance capabilities.

• Foundation for digitalization: This integrated infrastructure provides the essential foundation for seamless integration of IIoT, Industry 4.0/5.0 initiatives, and advanced analytics spanning from the deepest field devices to enterprise-grade cloud platforms.

HydITEx transforms the existing unidirectional PoE Ethernet system into a smarter, explosion-proof bidirectional architecture. Ex Dep IEMS Ethernet integration with Ex Ethernet UTP 1000 1Gigabit and Ex Ethernet STP 10G 10Gigabit. Ex Dep IEMS Ethernet safely transmits up to 1000 W of power over a distance of 100 m (for hydrogen). The combination of explosion-proof digital power supply, IEMS and industrial Ethernet capabilities into the Ex Dep IEMS Ethernet system provides the necessary infrastructure to fully implement Industry 4.0/5.0 and Industrial Internet of Things (IIoT) initiatives in hazardous environments.