Explosion Proof Battery Management System (Ex BMS)
Lead Acid and Nickel Cadmium batteries generate flammable hydrogen gas during the charging process. Various factors, including overcharging and excessive heat, can accelerate hydrogen production, leading to an elevated fire risk, explosion, and material deterioration.
In instances where ventilation within the battery room is inadequate, there exists likelihood of hydrogen accumulation. Adhering to the guidelines specified in the IEC60079-10-1 standard, the battery area is categorized as either Zone 1 or Zone 2 IIC T3. Consequently, all equipment installed in the battery room must be designed to meet the minimum requirements of IIC T3 as outlined in the IEC60079-14 standard.
CAPESERVE ENERGY Explosion Proof Battery Management System (Ex BMS) integrates seamlessly with our resilient hardware devices, providing a dependable solution for monitoring and collecting battery data. Designed to meet the stringent flameproof Ex technique outlined in ATEX directives and the IECEx equipment certification scheme, our hardware devices are strategically installed in battery rooms and hazardous areas. This professional-grade solution ensures reliable data acquisition while offering intelligent software dashboards for comprehensive visualization.
ATEX & IECEx Certified Battery Management System for Hazardous Areas
- Suitable for Zone 1 or Zone 2 IIC T6 hazardous area – II 2 G D Ex db IIC T6 Gb IP66
- Explosion Proof Battery Management System components Sensor, Hub and CT installed in battery room are Ex certified.
- Optional Ex Controller for hazardous area.
- All sensor leads, cables, BBus interface, CAT6 cables are meeting IEC60079-14 cable requirement.
- Site installation work and time saving due to all cable glands & termination done at factory.
- ATEX and IECEx Certification – Component level.
- ATEX & IECEx Certification – System Level.
Essential Parameters Monitored
- Cell Voltage
- Cell Impedance
- Cell Temperature
- String Voltage
- String Current
- Ambient Temperature
- SOC & SOH
Reporting Service
- Complete awareness of the overall condition of your batteries
- Assurance any battery issues will be identified to enable a timely response
- Reduce the internal effort required for monitoring battery performance data
Key Features
- Ni-Cd, 2V, 4V, 6V, 8V, 12V, 16V solutions.
- Simultaneous voltage sampling across all batteries.
- Temperature measured at negative terminal as per IEEE guidelines.
- 750Vdc optical isolation.
- Factory terminated harness.
- Cabinet or rack compatible.
- On-board high precision reference for impedance self-calibration.
Key Features
- Simple installation, minimal cabling and the capability to monitor UPS batteries that are up to 8 strings per system.
- A user-friendly web interface with smartphone/tablet friendly status screens.
- ATEX & IECEx Certification – System Level.
- Battery behaviour captured accurately through non-latching alarms, providing high resolution record of battery readings that cross two level alarm limits. Also captures the extreme values recorded during alarms.
- Integration with infrastructure management systems enabled with built-in protocols like SNMP, ModbusTCP, HTTP, DNP3 (Optional).
- Access options for non-networked sites, including LCD version of the Controller LX with keypad access, and simplified data collection option with USB port.
Battery Management Software
Our battery management software is a window into the health and performance of your battery systems. It enables you to make informed decisions quickly and proactively. Bundled with our Explosion Proof Battery Management System, the software application manages the Controller and records all battery readings in its database for viewing, trending, and reporting.
Data is turned into actionable information in the form of alerts and dashboards. The software also sends key information to the control room and facility management systems. Available across sites and to multiple users, our software comes with no additional licensing or costs.
ExBMS System Benefits
Downtime Prevention
Production stoppage reduced,increase in safety and higher savings on annual preventive maintenance
Thermal Runaway Prevention
Prevents hazardous situations likeovercharging, over-discharging,overheating, or short-circuiting. Monitors and mitigates risks suchas thermal runaway
Increase Shelf Life of Battery
Monitors and controls chargingcycles to minimize degradation.Maintains cells within safeoperating parameters, reducingwear and tear
Minimizing Carbon Footprint
The assigned support team orindividual investigates the reportedissue or fulfills the requested service.
Cost Savings
Reduces long-term costs by prolonging battery life and improving energy efficiency. Prevents the need for frequent replacements or emergency repairs.
Data Logging & Analytics
Tracks battery performance metrics overtime. Aids in diagnosing faults, identifyingtrends, and optimizing usage patterns.
Frequently Asked Questions (FAQ) |
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| Q1: What is an Explosion-Proof Battery Management System (Ex BMS)? |
An Explosion-Proof Battery Management System (Ex BMS) is an advanced monitoring and control solution specifically designed for batteries operating in hazardous areas, such as oil & gas facilities, petrochemical plants, mining operations, and chemical processing environments. Unlike standard battery management systems, an Ex BMS is engineered and certified according to IECEx and ATEX international safety standards, ensuring it can be safely installed in Zone 1 and Zone 2 explosive atmospheres where flammable gases, vapors, or dusts are present. The Capeserve's Ex BMS continuously tracks and manages key battery parameters including voltage, current, impedance, temperature, State of Charge (SOC), and State of Health (SOH). By doing so, it prevents common risks such as overheating, overcharging, deep discharge, and potential thermal runaway, which could otherwise create ignition sources in explosive environments. This makes an Ex BMS a mission-critical safety solution for industries that depend on reliable, certified power backup systems. |
| Q2: Why is an Ex BMS critical for oil & gas and hazardous industries? |
In hazardous industries like oil & gas, offshore drilling, refineries, LNG terminals, petrochemical plants, and mining, batteries are often used to power Uninterruptible Power Supply (UPS) systems, emergency lighting, fire & gas detection systems, and safety instrumented systems (SIS). These batteries operate in environments where explosive gases, vapors, and dusts are present, making safety and reliability a top priority. Without a certified Ex BMS, batteries are at risk of voltage imbalance, overheating, leakage, or failure—all of which can compromise safety, compliance, and uptime. The Capeserve Explosion-Proof Battery Management System is essential because it not only provides real-time monitoring and predictive maintenance but also ensures compliance with IEC 60079, IECEx, and ATEX regulations. By adopting an Ex BMS, companies can reduce downtime, extend battery lifespan, improve operational efficiency, and demonstrate commitment to international safety standards a key requirement when working with major operators. |
| Q3: What parameters does the Capeserve Ex BMS monitor? |
The Capeserve Explosion-Proof Battery Management System provides comprehensive 24/7 monitoring and detailed analysis of critical battery health indicators to ensure maximum safety, compliance, and performance. Key parameters monitored include:
This detailed monitoring capability allows for predictive maintenance, helping operators identify issues before they lead to failure. The Ex BMS integrates seamlessly with SCADA and DCS systems using protocols like SNMP, ModbusTCP, and DNP3, making it suitable for oil & gas refineries, offshore rigs, power plants, and hazardous chemical facilities. |
| Q4: What certifications does Capeserve’s Ex BMS comply with? |
The Capeserve Ex BMS is fully compliant with internationally recognized safety standards for hazardous areas, including:
By meeting these certifications, the Capeserve Explosion-Proof BMS provides assurance that it can be safely deployed in Zone 1 and Zone 2 hazardous environments across industries. Compliance with IECEx and ATEX not only protects personnel and assets but also supports adherence to safety regulations and requirements. |
Q5: How can I integrate Capeserve’s Ex BMS into my operations? |
The Capeserve Explosion-Proof Battery Management System is designed with flexibility and ease of integration in mind. It is compatible with lead-acid and nickel-cadmium batteries (1.2V to 16V per cell) and features optical isolation and ISO-calibrated sensors for maximum accuracy. The system supports seamless integration with industrial monitoring platforms through communication protocols such as SNMP, ModbusTCP, and DNP3, allowing direct connectivity to SCADA, DCS, and Energy Management Systems. Operators can access real-time data dashboards through a secure web interface, which is optimized for PCs, tablets, and smartphones enabling remote monitoring from anywhere. This empowers maintenance teams to receive instant alerts, generate compliance reports, and perform data driven predictive maintenance. Capeserve provides end-to-end support, including system design, installation, commissioning, training, and after-sales service, ensuring a smooth transition for companies in the oil & gas, petrochemical, mining, and power sectors. With our expertise in IECEx, ATEX, and hazardous area compliance, Capeserve ensures your battery systems are safe, reliable, and future-ready. |