Wi-Fi 6 in Hazardous Environments: Advancing Industrial Connectivity Safely

As industrial operations increasingly rely on wireless connectivity, the demand for robust, high-performance networking solutions in hazardous environments has never been greater. Wi-Fi 6 (802.11ax) emerges as a transformative technology, offering enhanced speed, capacity, and efficiency tailored for complex industrial settings. Specialized manufacturers like Analynk Wireless are at the forefront, developing purpose-built Wi-Fi 6 antennas and explosion-proof enclosures explicitly designed for Class I Division 1 Groups C & D hazardous locations, ensuring safety compliance and optimal performance.

The Advantages of Wi-Fi 6 in Hazardous Industrial Environments

Enhanced Performance and Capacity

Wi-Fi 6 introduces significant improvements over its predecessors, delivering up to 40% higher data rates (with a maximum theoretical throughput of 9.6 Gbps compared to 6.9 Gbps with Wi-Fi 5) and dramatically reducing latency by up to 75% in high-density environments. Technologies like Orthogonal Frequency Division Multiple Access (OFDMA) and Multi-User Multiple Input Multiple Output (MU-MIMO) enable simultaneous data transmissions to multiple devices, significantly enhancing network efficiency. This is especially beneficial in industrial environments where numerous sensors, machines, and control systems operate concurrently, potentially involving thousands of IoT devices spread across expansive areas.

Energy Efficiency

The Target Wake Time (TWT) feature in Wi-Fi 6 schedules communication times for devices, allowing them to enter low-power states when not transmitting data. This significantly conserves energy, potentially extending battery life by up to seven times under optimal, periodic communication scenarios. It also reduces maintenance needs and operational costs in hard-to-access hazardous locations where battery replacement poses safety risks and can interrupt production.

Improved Security

Security is paramount in hazardous environments where network breaches could impact critical safety systems. Wi-Fi 6 supports WPA3, the latest security protocol, offering enhanced protection against unauthorized access and ensuring data integrity through improved encryption and authentication methods. This advanced security is critical for industries such as oil and gas, chemical processing, and pharmaceutical manufacturing, where secure and reliable communication is essential for safety and operational continuity.

Implementation Requirements for Hazardous Areas

Explosion-Proof Enclosures and Certifications

Deploying Wi-Fi 6 in hazardous locations requires specialized hardware that meets stringent safety standards. While some industrial applications may suffice with Class I Division 2 or ATEX Zone 2 ratings, truly hazardous environments with continuously present flammable gases, vapors, or dust require more robust protection. Analynk's hazardous area access point enclosures are specifically engineered for Class I Division 1 Groups C & D environments—offering the highest level of security for areas where ignitable concentrations of gases or vapors can exist under normal operating conditions.

These enclosures feature:

• Explosion-proof construction designed to safely contain internal ignitions, preventing external flame propagation.
• Specialized glands and seals maintain enclosure integrity while allowing cable entry.
• Passive heat dissipation methods are built into the enclosure to keep internal electronics within safe operational temperature limits.
• Third-party certifications such as UL (North America), ATEX (European Union), and IECEx (International) verify compliance with global safety standards.

Antenna Design and Installation Considerations

A critical aspect of implementing Wi-Fi 6 in hazardous areas is the antenna system, which must extend outside the metal enclosure to function effectively while preserving safety integrity. Specialized antennas like Analynk's HazaLynk™ series include:

• Explosion-proof construction rated for hazardous classifications.
• Wide operating temperature ranges (-40°C to +60°C) suitable for extreme industrial environments.
• The impact-resistant design ensures durability in harsh settings.
• Specialized mounting brackets and RF cable assemblies for hazardous locations.
• Frequency options cover 2.4 GHz and 5 GHz bands (Wi-Fi 6), with potential extension into the 6 GHz band for Wi-Fi 6E applications, depending on specific antenna models.

Proper installation requires careful planning regarding the following:

• Mounting locations optimize signal coverage and maintenance accessibility.
• Explosion-proof conduit systems for cable routing.
• Proper grounding and bonding to mitigate static electricity buildup.
• RF propagation characteristics in metal-rich industrial environments.

Network Interference and Reliability

Industrial settings often experience electromagnetic interference from motors, drives, and other equipment, potentially disrupting wireless signals. Wi-Fi 6 addresses this through features like BSS Coloring, which differentiates overlapping signals, reducing interference and enhancing reliability. Additionally, improved OFDMA modulation provides robust performance in noisy RF environments typical in industrial settings.

For mission-critical applications, implementations should include:

• RF site surveys before installation to identify interference sources.
• Strategic channel planning to avoid conflicts with existing wireless systems.
• Deployment of redundant access points where necessary.
• Ongoing performance monitoring and routine maintenance.

Integration with Legacy Systems

Many industrial facilities utilize legacy systems that may not immediately integrate with Wi-Fi 6. Effective integration strategies include:

• Protocol converters bridging modern Ethernet/IP communications with older industrial protocols.
• Edge gateways collecting legacy equipment data for transmission via Wi-Fi 6.
• Wireless access points supporting older Wi-Fi standards during transition phases.
• Phased implementation strategies minimizing operational disruptions.

Real-World Applications and Benefits

Wi-Fi 6 is already delivering significant benefits across hazardous industries:

• Oil and Gas: Refineries utilize explosion-proof Wi-Fi 6 networks for real-time sensor monitoring, predictive maintenance, and downtime reduction.
• Chemical Processing: Wi-Fi 6 enables mobile workers to access digital tools and remote expertise safely, maintaining intrinsic safety.
• Pharmaceutical Manufacturing: Facilities employ Wi-Fi 6 to support automated guided vehicles and continuous environmental monitoring in sterile, explosion-risk areas.

Integrating Wi-Fi 6 into hazardous industrial environments significantly enhances wireless communications' reliability, efficiency, and security. Successful implementation demands careful attention to explosion-proof enclosures, certified antenna systems, and precise installation practices. With industry leaders like Analynk developing specialized Wi-Fi 6 solutions for hazardous areas, industrial operations can confidently leverage advanced wireless technology without compromising safety. Partnering with manufacturers experienced in wireless technology and unsafe environment standards enables organizations to navigate complex implementation requirements effectively, unlocking the full potential of Wi-Fi 6 in even the most challenging industrial settings.

Analynk Wireless
(614) 755-5091
https://analynk.com

Industrial Safety Meets Advanced Performance: Analynk Soon to Launch Wi-Fi 6 Antennas for Hazardous Areas

Wi-Fi 6, also labeled 802.11ax, represents a significant step forward in wireless networking for industrial operations, especially those with challenging requirements and hazardous areas. Many industrial sites, such as chemical plants, refineries, and grain handling facilities, face strict safety standards because of flammable gases, combustible dust, or volatile materials. These locations require robust and certified equipment that can deliver top-tier performance and an uncompromising level of safety.

The immense capacity of Wi-Fi 6 stands out in busy industrial environments, where machines, sensors, and control systems generate massive amounts of data. This technology leverages Orthogonal Frequency-Division Multiple Access (OFDMA) and multi-user multiple-input and multiple-output (MU-MIMO) to coordinate traffic more effectively. It assigns bandwidth to devices without creating bottlenecks and maintains smooth performance even when dozens—or hundreds—of units operate simultaneously. This high reliability helps maintain continuous production, reduce downtime, and enable real-time analytics.

Energy efficiency also plays a key role in modern industrial settings. Wi-Fi 6 introduces Target Wake Time (TWT), which schedules specific intervals for devices to transmit and receive data. When sensors or other equipment only need occasional connectivity, TWT allows them to enter low-power states between transmissions, significantly reducing energy use. Over time, this reduction in power consumption lowers overall costs, extends battery life for portable devices, and eases maintenance demands.

Safety and security remain paramount in hazardous areas, and Wi-Fi 6 meets those concerns with advanced encryption protocols such as WPA3. These enhancements help shield networks from unauthorized access and preserve data integrity. Industrial plants that run critical systems demand a network infrastructure they can trust, and Wi-Fi 6 delivers that reliability through robust safeguards.

Analynk Wireless of Columbus, OH, recognizes the importance of secure and reliable connectivity in hazardous areas. The company will soon release a specialized line of Wi-Fi 6 antennas explicitly engineered for these high-risk environments in response to growing demand. Analynk has built a reputation for designing products that withstand harsh conditions, and these new antennas continue that tradition. They include rugged enclosures that stand up to chemicals, dust, and extreme temperatures, along with certifications that ensure safe operation in zones prone to explosions or fires. By pairing Wi-Fi 6’s advanced features with a hardware design that meets rigorous safety standards, these antennas offer a cutting-edge solution for critical industrial applications.

With Wi-Fi 6 and its high-capacity, low-latency performance, facilities can connect more devices without experiencing congestion or drops in network speed. They can also support advanced automation, remote monitoring, and predictive maintenance without compromising worker safety or data security. Analynk’s soon-to-be-released Wi-Fi 6 antennas expand those possibilities by giving hazardous-area operators access to state-of-the-art wireless connectivity. As industrial operations embrace digital transformation, Wi-Fi 6 will serve as a crucial backbone that propels efficiency, reduces downtime, and fosters innovation in some of the harshest environments on earth.

Analynk Wireless
(614) 755-5091
https://analynk.com

Class I, Groups C and D, ATEX/IECEx Certified Hazardous Area Antennas

Class I, Groups C and D, ATEX/IECEx certified omnidirectional hazardous area antennas are vital to maintaining reliable wireless communication within environments prone to explosions due to flammable gases, vapors, or mists. These antennas, designed explicitly for such high-risk areas, meet stringent international safety standards set by ATEX (Atmosphères Explosibles) and IECEx (International Electrotechnical Commission System for Certification to Standards Relating to Equipment for Use in Explosive Atmospheres).

The "Class I" designation identifies locations where flammable gases or vapors exist, with Group C environments containing gases like ethylene and Group D environments involving substances such as propane and gasoline. These antennas undergo a rigorous testing and certification process, ensuring they can operate safely without becoming a source of ignition, thereby preventing potential explosions in hazardous areas. This thorough process provides a high level of reassurance about the safety of these antennas.

Manufacturers design these antennas to avoid any ignition sources, including sparks or excessive heat, which could trigger an explosion. The construction materials resist corrosion, static electricity buildup, and mechanical stress, while the housings often feature flame-proof enclosures or intrinsically safe designs to contain any potential electrical faults.

The omnidirectional capability of these antennas allows them to transmit and receive signals in all horizontal directions, providing 360-degree coverage. This feature proves essential in hazardous facilities like oil refineries, chemical plants, or offshore platforms, where consistent and reliable communication is crucial for safety and operational efficiency.

Industries employ these antennas in various wireless communication systems within hazardous areas. They play a key role in industrial control and monitoring systems, enabling real-time data transmission from sensors and equipment. This capability ensures that crucial data is always available, enhancing safety and operational efficiency. Emergency communication networks rely on these antennas to ensure worker safety and coordinate responses during incidents. Additionally, voice communication systems for personnel and telemetry systems for remote monitoring and control of equipment in hazardous locations utilize these antennas.

Technicians installing these antennas must adhere to strict guidelines to maintain the integrity of the hazardous area classification. This process often involves using specialized cable glands, conduits, and mounting hardware that meet the required safety certifications, ensuring that the entire system operates safely within the designated hazardous environment. Adhering to these guidelines is crucial to maintaining the high safety standards of these antennas.

Deploying Class I, Groups C and D, ATEX/IECEx certified omnidirectional hazardous area antennas enables companies to harness modern wireless technologies while maintaining stringent safety standards. These antennas enhance operational efficiency, improve worker safety, and ensure regulatory compliance in industries dealing with hazardous materials.

Analynk Wireless
(614) 755-5091
https://analynk.com

Hazardous Area Antennas

Hazardous area antennas are specialized types of antennas designed for use in environments with a risk of explosion or fire. These environments, known as hazardous areas, are typically found in industrial manufacturing facilities such as oil refineries, chemical plants, and mines.

Hazardous area antennas transmit wireless signals in these environments, allowing for the remote control and monitoring of equipment and machinery. These transmissions are essential for the safe and efficient operation of industrial manufacturing facilities, as it allows for the monitoring of critical systems and the ability to shut down equipment in the event of an emergency.

Several types of hazardous area antennae are available, including omnidirectional, directional, and panel antennas. Omnidirectional antennas emit a signal in all directions, while directional antennas emit a signal in a specific direction. Panel antennas provide long-range communication.

The most common hazardous area antenna used in industrial manufacturing facilities is the explosion-proof antenna. The construction of these antennas includes materials that can withstand the high temperatures and pressures that can occur in an explosion. They also have a flameproof design that prevents fire from spreading in the event of ignition.

Another hazardous area antenna commonly used in industrial manufacturing facilities is the intrinsically safe antenna. These antennas operate at a level that is below the ignition threshold of flammable gases or dust, which eliminates the risk of explosion or fire.

In addition to these types of hazardous area antennae, wireless mesh networks operate in these environments. These networks allow a wireless network that connects multiple devices and systems, providing real-time monitoring and control of equipment and machinery.

Overall, hazardous area antennae are essential for industrial manufacturing facilities' safe and efficient operation. They allow for the remote control and monitoring of equipment and machinery, which is crucial in preventing accidents and ensuring the safe operation of these facilities.

Analynk Wireless
(614) 755-5091

CTX/CTM Series Hazardous Area 4G LTE Explosion Proof Antennas

The Analynk CTX/CTM 4G LTE antennas are designed for use in “Hazardous-Classified” and Industrial-Hardened applications. The antennas are omnidirectional, with an average gain of 1.27dBi with a peak gain of 2.46 dBi. Two antenna versions are available, the CTX series has a 3/4” NPT mount, and the CTM series has an M20 mount. The antennas can be mounted on an Explosion Proof enclosure or conduit. The mounting base is made of heavy nickel-plated brass with an integrated TNC-F connector for ease of installation. The radome is optimized for rugged industrial applications while maintaining maximum radio frequency transmission and reception efficiency. The antennas have a built in Explosion Proof seal and may be mounted up to 18” away from the enclosure without an additional seal.

Get more information and download a specification sheet here.

Analynk Wireless
(614) 755-5091

Coming This June: Analynk's Hazardous Area 4G LTE Antenna

Analynk Wireless, an innovative manufacturer of hazardous area antennas and access point enclosures and wireless instrumentation for the process control industry, announced a 4G LTE antenna rated for Class I, Division 1 Groups C & D, ATEX, and IECEx Zone 1 areas.

4G, which stands for "Fourth Generation," is a standard developed by the International Telecommunications Union (ITU) in 2008, established explicitly by the ITU-R. (which deals with radio communications). Today, 4G is better known for its broadband capabilities and dramatically higher speed than 3G, which pioneered data access in the cellular space. 

The ITU standard mandated a minimum download speed of 100 Mbps, which was highly hypothetical at the time. In reality, several years later, carrier networks are only now realizing these goals. A wireless network must be capable of downloading at a rate of at least 100 Mbps to qualify as true 4G.

Analynk will introduce the new product this June 2021.

For more information, contact Analynk Wireless, LLC, 790 Cross Pointe Road, Columbus, OH 43230

Call them at 614-755-5091 or visit https://analynk.com.

Antennas Designed for Hazardous-Classified, Industrial Hardened Applications

Wireless communication has seen increasing prevalence in the industrial process measurement and control field for several years.  It has provided years of reliable communications for monitoring and controlling processes, where using cables is either too costly or impractical. The absence of wires saves space, reduces the potential for damage, and simplifies modifications to the equipment layout. Implementing wireless communications in hazardous areas, whether through WiFi or other radio frequency channels, presents a particular set of challenges to successful implementation. Points of network access and further transmission and receiving equipment can require a level of isolation and hardening appropriate for the hazardous environment. In response to customers' desire to incorporate the technology across an ever-widening array of application scenarios, vendors continue developing and releasing new products and technologies that expand the potential for industrial wireless communication.

Many industrial process control operations can benefit from wireless connections between measurement and control devices. Analynk Wireless provides patented hazardous area explosion-proof antennas for industrial installations. Analynk antennas are operable across an extensive temperature range and provide substantial impact resistance, signal output, and third-party ratings for hazardous environments. These rugged antennas are for global application in the industrial process control field. Analynk hazardous area antennas are very robust and intended for industrial applications. All hazardous area antennas have UL listed Class I, Groups C and D, ATEX/IECEx Certification, and range of frequencies available- from 900MHz, 2.4GHz, and Cellular GPS, 4G, Iridium, and dual bands.

For more information, contact Analynk Wireless.
(614) 755-5091

Methods of Isolating Electrical Equipment in Hazardous Areas

Background

Combustion or fire is a chemical reaction in which a combustible material combines with an oxidant to release energy. Part of the energy release is used to sustain the explosion, by utilizing existing heat or creating a vacuum to consume more oxygen.  Within a hazardous environment there are three elements necessary for a fire or explosion:

• A combustible material also known as a fuel 
• Ignition source - electrical arcing or general heat
• An oxidizer also known as oxygen

When a fuel, oxidizer and ignition source are present at the necessary levels, burning or explosion will occur. To reduce the possibility of fire or explosion, one of the key elements needs to be reduced or removed.

Another key factor in a fire or explosion are the explosive limits. These are the maximum and minimum concentration needed of a given combustible material to support a fire or explosion. To form an explosive mixture, the hazardous gas must have sufficient concentration levels. The minimum concentration of oxygen to combustible material is known as the lower explosive limit or LEL. If the concentration is below the LEL, it will not be flammable or have enough flammable material present. The same condition would apply if gas concentration is too rich, meaning it will not ignite because it will not have sufficient oxygen to sustain the fire or explosion. This is known as the upper explosive limit, or UEL. It should be noted that different gases will have different threshold limits.

In addition to the explosive limits, each hazardous material will have an autoignition temperature and a flashpoint. The flashpoint is the temperature at which the material will generate sufficient quantity of vapor to form an ignitable mixture. As the liquid is heated and reaches the flashpoint, autoignition could occur. An autoignition is the lowest temperature at which a combustible material will spontaneously ignite in a normal atmosphere. For example, if we have the heating of a combustible liquid, explosive vapors are created. As the material reaches the explosive limits creating the flashpoint. If the general atmosphere is increased, the autoignition temperature, fire, or explosion will occur.

To simplify, the specification of electrical devices into hazardous environments, IEC classification methods utilize autoignition, flashpoint, and explosive limits to place hazardous materials within groups.

The two predominant methods used for classification of hazardous environments are the NEC and IEC standards. IEC and NEC standards both classify the level of risk into three main categories:

• Continuous
• Occasional
• Not normally present

All three categories provide the likelihood of an explosive atmospheric condition within the general environments. Within the IEC standard, the general risk categories are then classified as Zones. This reflects the physical material that could provide a potential fire or explosion. From liquids and gases, the area classifications are Zone 0, Zone 1, and Zone 2. By altering the physical material to dust or fibers, the area classification numerical value changes to Zone 20, Zone 21, and Zone 22.

Referring back to the necessary requirements for an explosive triangle, we know we need ignition source, oxygen, gas and or dust combustible material in the correct mixture within the atmosphere. In order to specify electrical devices and hazardous locations, we need to identify the general Zones within each area. When working with liquids or gas, we locate the most hazardous or flammable location directly above the material. Due to the possibility of the valve leaking, at the top of the containment structure we must classify the area as Zone 1. As we move further away from the possible explosive atmospheric condition the Zone classification would be reduced to Zone 2. By altering the combustible material properties to a solid form, the area classification above the material would be Zone 20. If the dust escapes the same failed valve, the external area around the same containment unit would be classified as Zone 21. As we continue to move away from the containment unit and with reduction of Category risk, the new classification for the general area would be Zone 22.

Now that we know combustible materials whether liquid, gas and or dust will have different upper and lower explosive limits, and we understand the general heat could be the ignition source, within the IEC standards the T rating specifies the maximum surface temperature an electrical device will create. As the temperature increases, the associate rating will decrease, meaningless heat will have a higher T rating, while an increase in surface temperature will reduce the T number.

As a recap the IEC standards classify hazardous areas as environments that could contain explosive vapors, gases, and/or dust within the atmosphere. The primary categories provide the risk levels as constant, occasional, and not likely. Since elements have a variety of flammability and the physical properties could be different, IEC standards segment the types of combustible materials into Zone classifications. The most hazardous is Zone 0 or Zone 20. By reducing the risk level to have occasional explosive atmospheres the Zone classification is Zone 1 or Zone 21 and further reduction of Category risks would change the hazards classification to Zone 2 or Zone 22

Flameproof enclosure for
wireless access point (Analynk) 

Methods of Isolation/Protection

Let's take a look at each method of protection and the general application. To ensure safety in a given situation, equipment is placed in protective level categories. As mentioned before Category 1 is the highest safety level, making Category 3 the lowest risk and safety level. The general 8 protective methods are:

1. Flameproof enclosures
2. Sand encapsulation
3. Pressurization 
4. Oil encapsulation 
5. General encapsulation
6. Increased safety
7. Intrinsic safety
8. Non-sparking

A flameproof enclosure method is a type of protection where devices that are capable of igniting an explosive atmosphere are built inside an enclosure. This protective method prevents the transmission of the explosion to the external atmosphere surrounding the enclosure. This method of protection would be suitable for applications on:

• Power operated equipment
• Switchgear
• Motors
• Any equipment that produces ignition source during normal operation.

Sand encapsulation is a type of protection in which the enclosure of the electrical apparatus is filled with a finely granulated material. This ensures electrical arcs occurring within the electrical apparatus will not ignite the surrounding atmosphere.

Pressurization is a method of protection by which the entry of a surrounding combustible material is prevented by maintaining a protective gas within the enclosure. This is generally accomplished by creating a higher pressure within the enclosure than the surrounding atmosphere. This protective method would be used for any power operated equipment.

Oil encapsulation is a type of protection in which the electrical apparatus or part of the electrical apparatus are immersed within an oil-based fluid. The general application for this type of protection would be used for:

• Switchgear units
• Circuit breakers
• Transformers

Encapsulation is a type of protection in which the device that could ignite anexplosive atmosphere are enclosed within a resin. The material used would be resistant to environmental influences, heat and/or sparking from electrical components. The general application for this protective method would be used for:

• Electrical circuit boards
• Miniature motors
• Valves

Increased safety is a type of protection where measures are taken to prevent the possibility of high temperatures and the occurrence of ignition. This method includes the interior and external portions of the electrical apparatus. The general application for this protective method would include:

Connection and distribution boxes
Luminaires
Measuring instruments and devices that do not normally produce ignition within operation

Intrinsic safety is a protective method to ensure that the available electrical and thermal energy in the system is always low enough that the ignition of the hazardous atmosphere cannot occur. This is achieved by ensuring that only low voltages and currents enter the hazardous area as well as all electrical supply and signal wires are protected by safety barriers. The general application for intrinsic safety would be used for:

• Measuring and control engineering 
• Data engineering
• Low electrical valves

Non-sparking equipment and wiring process is a protective method where apparatuses are designed with low power levels and low stored energy. This ensures that arc produced during normal functionality of the equipment,  or as the result of equipment failure,  has insufficient energy to ignite the hazardous atmosphere. The general application for non-sparking protective methods would be used for:

• Motors
• Lighting
• Junction boxes
• Electrical equipment

All equipment certified for use in hazardous areas must be labeled to show the type and level of protection applied.

In summary hazardous locations could exist in multiple industries. The geographical location will dictate the general method used for classification. The European Standard or IEC provides guidance of risk into three main categories. These risk levels are then divided into Zones and have numerical values that relate to the possibility of explosive gases or dusts present within the atmosphere. Because combustible material could have a variety of explosive limits, the method of protection will be important. Nevertheless all electrical devices placed within hazardous environments will follow the device markings to ensure fire or explosion does not occur.

Hazardous Area Antennas

Gathering information in hazardous areas is critically important for plants to access. Wireless communications is vital for improved efficiencies, real-time monitoring of machinery and equipment, and the safety and well-being of personnel.

Hazardous area antennas from Analynk Wireless are designed and constructed for very rugged industrial applications. Furthermore, all Analynk hazardous area antennas  are UL  listed for Class 1, Groups C & D and have ATEX/IECEx Certification. Finally, a range of frequencies are available from 900MHz, 2.4GHz, Cellular, GPS, Iridium and dual bands.