Why the First Ex-Zone, Large-Display Controller with Hot-Swappable battery is a Game Changer
Industrial automation is changing rapidly, but hazardous areas have long struggled to adopt cutting-edge digital solutions. When Vision Remote and ADOTT Solutions set out to create a tablet-style controller for Zone 1, they faced a significant obstacle:
How do you design a full-featured, intrinsically safe controller with a big, bright display, hot-swappable battery, and robust wireless communications—without ever risking safety or compliance?
The road was full of pitfalls: displays, batteries, static discharge, power management, long-distance communication… So, how did they do it?
What are the main challenges in designing an Ex-zone tablet/controller?
Strict voltage and capacitance limitations for all components.
Display and backlight typically operate at high voltages.
Hot-swapping batteries are allowed only if the spark and overheat risk is 100% controlled.
Plastic enclosures can accumulate static energy, creating an ignition risk.
How did the ADOTT team overcome these issues?
Custom “boost protection” modules for safe display operation.
Proprietary Power Protection (PPEx) modules for energy management.
Pioneering use of solid-state batteries for maximum safety and runtime.
Antistatic, impact-resistant polyurethane housing—no compromise on usability.
What’s the breakthrough?
The first truly mobile, Zone 1-certified controller with all key modules intrinsically safe—and a success story already inspiring the next generation of industrial tablets.
