Answer #1:No. Our GasBoss*100 uses advanced catalytic bead techniques to out-perform and out-last any infrared sensor. There are no mirrors to fog when cold air enters the facility, no emitter bulbs to replace at a hefty expense, and no narrow range gas sensitivities that ignores unexpected contributors to the explosive mixture. Our demonstrated 20+ year MTBF can't be challenged by competitor's NDIR units having typically 5-7 year MTBF figures.

Answer #2: Further to the above, the GasBoss*100 is approved intrinsically safe, allowing lower cost installation by avoiding sealed conduit. There are no intrinsically safe NDIR sensors, only explosion proof, so figure on the full cost of XP installation, exacerbating the already pricey NDIR sensors. Considering the initial installation and long-term maintenance labor, the GasBoss*100 catalytic bead sensor with its long life and broad-range LEL response can save you a lot of money, while enhancing safety.

Answer #1: Yes. A computer system with telemetry can reduce the installation cost by half. Home run wiring to a central control panel requires miles of wire that raises the installation cost, while telemetry places convenient field I/O panels through your facility to collect the sensor cabling, requiring just a single pair of wires between panels for telemetry.

Answer #2: Yes, again. The computer collects and consolidates all the sensor data and displays it effectively for easy viewing. Management can view the sensor values and alarm conditions quickly in one office, rather than chasing around the plant checking panel modules. Remote workstations can be networked to the central computer for displaying and analyzing key information to specialty staff.

Answer #3: Further to the above... Data and alarm logging is included with the computer software, providing archival files for offline analysis. Called data mining, this opens the door for optimizing your operations, based on prior history and events. Hard wired panels have no memory or displays for storing data or illustrating it functionally or geographically... thus no history is available.

Answer #4: Still more... MagiKal/DX automatic gas sensor calibration is a powerful feature that is available through our Millennia-DX computer software and telemetry. This performs calibration of every gas sensor in the system on a monthly or weekly schedule, all without any human intervention. Any failing sensors are flagged for service. The savings in technician labor is obvious, but there are other benefits, such as: extending sensor life, avoiding fines, lower cal-gas cost, eliminating human errors, printed documentation and improving safety.

Answer #1: First off, send us a sketch showing what you have in place. There are many ways to retrofit an alien (i.e. not Rel-Tek) installation by adding a computer, adding telemetry and even adding a MagiKal/DX automatic sensor calibration system for your existing sensors. Our applications team will review this information and make recommendations -- at no cost or obligation to you. Then, on your OK, we will work with your contractor or in-house electrician to upgrade the system with minimum disruption to your operations.

Answer #2: If your gas monitoring system is working satisfactorily, but requires a lot of routine maintenance to calibrate the gas sensors, we can just add automatic calibration without the need for any major equipment change. We do this with our OmniKal packages that intercept the 4-20ma signals from your gas sensors and generate new, calibrated 4-20ma signals that flow to your existing monitoring/alarm equipment. The OmniKal comes in 1, 4, 8, 12 and 16 sensor interface modules that are invisible to your present monitoring. These modules contain microprocessors that perform group calibrations on a weekly or monthly schedule for a year or more without attention.

Answer #1:Yes, and much more. Our Millennia-DX monitoring and control software has a visual control setup scheme where Boolean operators are connected logically using "virtual wiring."All the normal operators (or, and, inverters, etc.) are selected using click and drag commands. Inputs and outputs are selected, applied and identified. There are timers and calendar scheduling operators, as well as flip-flops, pulse generators and control expanders. Twelve pages are available for constructing large and complex strategies. The best part is that active control paths are shown in red, facilitating the tracking of controls and diagnostics.

Answer #2: More to above... Build as many screens as you wish using the draw tools included. Draw lines, ellipses, and boxes. Import bit maps from scanned drawings and photos. Insert hot buttons for click-on controls. Add digital and analog meters, as well as 8-color graphs and bar charts. Introduce sliders for changing process control set points. Type explanatory text using whatever fonts and colors you wish. Set any number of threshold crossings for analog alarm and control. Link color changes, vertical and horizontal fill, rotation, displacement and even visibility to parametric values and states. Put your logo on the screens to customize the final configurations.

Answer #3: Still more... Install around your plant a variety of I/O cards having various numbers of analog (12-bit) inputs, digital (dry contact) inputs, analog (12-bit) outputs and digital (relay) outputs. Use as many as 253 card addresses. Communicate at up to 115.2k-Baud for 20 miles over a twisted pair of wires. Network to any number of workstations via a LAN. Dial in over a phone lie to interrogate and adjust the computer parameters. Set up 26 layers of passwords for security. Millennia-DX is world-class software that can do just about anything.

Answer #1: Our strength is that we do not need to buy in a lot of high priced third party components and software to make up a system. We manufacture everything. Therefore, our system pricing is astoundingly low, considering the features included. For example, Rel-Tek's full size software package is priced at a third of what others charge for a knockdown runtime package. And, we throw in the graphics tool kit, control setup up tools and logging modules to boot.

Answer #2: We offer features that no one else does. Consider automatic sensor calibration... We developed this technology in house and applied for patent last year. To our knowledge, no competitor offers this feature, at any cost. There are a dozen of these systems operating around the country, and the clients would not give them up for anything. Rel-Tek is the designated supplier of automatic calibration systems to the Allegheny County Port Authority for its Pittsburgh/Airport Bus way Tunnels.

Answer #3: Long component life spells lower cost. Our sensors tend to have useful lives about twice that of competing products. Combining this fact with a lower maintenance effort, we should charge twice the competitor's prices; but we don't!

Our systems were originally designed and engineered for use in the coal mining industry, where computer experts just aren't available. Making our systems intuitive enables unskilled workers to use, maintain and even modify the systems in their mines and plants. If you have a question or need assistance, we can usually provide this by a phone or modem link. By keeping a few spare parts in stock, there is virtually no need for an "expert" to visit the site. If a meltdown does occur -- say, due to a computer hard drive crash, a lightning strike or other power surges, etc. -- then we stand ready to visit the site on short notice and sort out the problem.

Calibration verifies the precision and reproducibility of measurement instruments, such as sensors and measuring systems. Sensors that are calibrated are the prerequisite for precise, reliable and reproducible measurement results. Calibration is one of the key prerequisites for effective quality assurance.

A catalytic bead sensor is a type of sensor that is used for combustible gas detection from the family of gas sensors known as pellistors.

The catalytic bead sensor consists of two coils of fine platinum wire each embedded in a bead of alumina, connected electrically in a Wheatstone bridge circuit. One of the pellistors is impregnated with a special catalyst which promotes oxidation whilst the other is treated to inhibit oxidation. Current is passed through the coils so that they reach a temperature at which oxidation of a gas readily occurs at the catalysed bead (500-550 °C). Passing combustible gas raises the temperature further which increases the resistance of the platinum coil in the catalysed bead, leading to an imbalance of the bridge. This output change is linear, for most gases, up to and beyond 100% LEL, response time is a few seconds to detect alarm levels (around 20% LEL), at least 12% oxygen by volume is needed for the oxidation.

LEL stands for “Lower Explosive Limit” and is the lowest concentration of a particular gas that has the potential to be flammable or combustible. In other words, it’s the minimum amount of gas that will catch fire or explode when an ignition source is present. If a gas concentration is less than the lower limit, there is insufficient gas for the mixture to ignite.

Calculate air flow in a duct by measuring the air flow velocity in feet per minute (FPM) and multiplying by the duct cross sectional area in square feet (ft2).

The linear response of the catalytic bead sensor makes it very easy to predict its response to various gases and provide a correlation factor based on virtually any gas used for calibration. But most importantly, infrared sensors are not capable of detecting hydrogen.

Catalytic beads can detect more combustible gases which may make it the more appropriate choice in certain applications vs. NDIR sensors.

The sensor has many advantages such as continuous operation, long lifespan, robustness, simple to operate, easy to install and calibrate. It can be used for H2 detection at industries like heavy water plants, oil refineries, nuclear reactors, research laboratories etc.

Spillage Switch is designed to trip and shutdown the conveyor system when a predetermined amount of spillage is present to activate the switch (pressure plate). This helps to eliminate buried head and tail pieces of the conveyor belt.

Why Catalytic Bead Gas Sensors Still Crush “Modern” Industrial Sensors in Real-World Safety

Catalytic bead gas sensors have been protecting lives for decades—yet they’re constantly declared “obsolete” by vendors pushing infrared, MOS, and digital gas detection technologies. The irony? In real industrial environments, catalytic bead (pellistor) sensors consistently outperform many modern gas sensors where it matters most: accuracy, reliability, and trust under harsh conditions.

So why are plants, refineries, and mines still relying on a technology invented last century? Because it works.

Old Technology, Unbeatable Physics

Catalytic bead gas sensors measure combustible gases using a simple, brutally effective principle: actual oxidation. When a flammable gas contacts the catalyst, it burns. That heat change is directly measured and translated into gas concentration.

No modeling. No assumptions. No software guesses.

Modern industrial gas sensors often rely on indirect measurement—infrared absorption curves, semiconductor surface reactions, or algorithmic compensation. These approaches are elegant in theory and fragile in practice.

When safety is non-negotiable, direct physics beats clever math every time.

Built for Real Industrial Environments (Not Marketing Demos)

Search for “industrial gas sensor reliability” and you’ll find a pattern: modern sensors shine in labs and stumble on plant floors.

Catalytic bead sensors thrive where others struggle:

• • High humidity
• • Dust and particulate contamination
• • Mechanical shock and vibration
• • Wide temperature swings
• • Long-term continuous exposure

Infrared gas sensors suffer from window fouling. MOS sensors drift unpredictably. Electrochemical sensors age, dry out, or poison easily.

Catalytic bead sensors? They just keep detecting gas.

Predictable Failure Is a Feature, Not a Flaw

Every gas sensor fails eventually. The difference is whether it fails honestly.

Catalytic bead sensors fail in ways maintenance teams can see, test, and verify:

• • Sensitivity loss is obvious
• • Bump tests reveal degradation
• • Replacement timing is predictable

Many modern industrial sensors fail quietly. Internal diagnostics may still show “OK” while detection accuracy drops. Software compensation hides the problem—until it’s too late.

In safety systems, silent failure is the most dangerous failure.

Calibration That Doesn’t Require a PhD or Firmware Update

Catalytic bead gas sensors are loved by technicians for one reason: they behave consistently.

• • Linear response across the LEL range
• • Simple, well-understood calibration methods
• • No proprietary software ecosystems
• • No vendor lock-in just to verify performance

Modern sensors often require specialized tools, encrypted interfaces, and trained specialists—introducing operational risk completely unrelated to gas detection.

Safety equipment should reduce complexity, not add to it.

One Sensor, Many Gases

A major advantage of catalytic bead sensors is their broad-spectrum detection. They respond to the combustion energy of flammable gases—hydrocarbons, hydrogen, solvents, and mixed gas environments.

Many modern sensors are narrowly optimized:

• • Tuned for methane but weak on hydrogen
• • Accurate for one gas, unreliable for blends
• • Dependent on lookup tables and assumptions

Industrial environments don’t stay neatly categorized. Catalytic bead sensors don’t need them to.

“Modern” Doesn’t Automatically Mean “Safer”

Smart dashboards, wireless connectivity, cloud analytics—these are useful features. But none of them improve safety if the underlying sensor can’t be trusted.

A perfectly connected sensor that misreads gas concentration is worse than a standalone sensor that tells the truth.

That’s why catalytic bead sensors remain the backbone of combustible gas detection in safety-critical industries.

Why Catalytic Bead Sensors Are Still the Industrial Gold Standard

Despite endless claims of obsolescence, catalytic bead gas sensors continue to dominate in oil & gas, chemical processing, mining, and manufacturing for a reason:

• • They detect real combustion, not estimates
• • They survive harsh industrial conditions
• • They fail visibly and predictably
• • They’re easy to maintain and calibrate
• • They work across a wide range of combustible gases

In industrial safety, trust beats novelty.

Final Thought: Boring Tech Saves Lives

Catalytic bead sensors aren’t exciting. They don’t trend on LinkedIn. They don’t come with buzzwords.

What they do is keep people alive—day after day, year after year.

And in industrial gas detection, that’s the only metric that matters.

Catalytic Bead Sensors: The Best Gas Detection Technology for Mining Safety

In the mining industry, safety is paramount. With the constant threat of hazardous gases such as methane, hydrogen sulfide (H₂S), and carbon monoxide (CO), reliable gas detection is critical for protecting workers and ensuring safe operations. While various gas detection technologies are available, catalytic bead sensors have stood the test of time, offering unmatched reliability, accuracy, and cost-effectiveness for the mining sector. Here’s why catalytic bead sensors are the best fit for mining gas detection.

1. Robust Performance in Harsh Mining Conditions

The mining industry is notorious for its extreme conditions, from dust and high humidity to vibration and temperature fluctuations. Catalytic bead sensors are built to handle these challenges, offering superior durability in environments where other sensor types might fail.

• • Dust and Dirt Resistance: Catalytic bead sensors are less likely to fail due to dust, dirt, or particulates, making them ideal for underground mining.
• • Vibration Resistance: Mining equipment is constantly exposed to vibrations from machinery, blasting, and drilling. Catalytic bead sensors can maintain stable performance even under these conditions.
• • Wide Temperature Range: Catalytic bead sensors can operate in both freezing and extremely hot conditions without losing accuracy.

2. Reliable Detection of Combustible Gases

One of the most dangerous gases in mining is methane, a highly combustible gas found in underground coal mines. Methane can accumulate in confined spaces, creating a serious risk of explosions. Catalytic bead sensors are highly effective in detecting methane and other combustible gases, providing early warnings to prevent accidents.

• • Proven Technology: Catalytic bead sensors have been the go-to solution for methane detection in mining for decades, offering a proven and reliable technology for gas detection.
• • Fast Response: These sensors provide quick detection of even small concentrations of gas, ensuring that dangerous levels are identified before they become hazardous.

3. Low Maintenance and Cost-Effective

Cost control is essential in mining operations, and catalytic bead sensors offer a cost-effective solution for long-term gas detection. They are simple to maintain, with minimal downtime and low replacement costs compared to more complex sensor types.

• • Simple Maintenance: Catalytic bead sensors are easy to maintain, requiring only periodic bump tests to ensure they are functioning correctly.
• • Long Lifespan: With a long operational life, catalytic bead sensors are built to last, reducing the need for frequent replacements.
• • Affordable Calibration: The calibration process is straightforward and cost-effective, unlike more complex sensor technologies that require specialized equipment.

4. High Versatility in Gas Detection

Mining operations are often exposed to multiple gases that can pose a threat. Catalytic bead sensors are highly versatile and can detect a wide range of combustible gases, including methane, carbon monoxide, and hydrogen. This versatility makes them a great all-in-one solution for gas detection in mining.

• • Broad Gas Detection: A single catalytic bead sensor can detect multiple combustible gases, allowing mining operations to monitor for a range of hazardous gases with fewer sensors.
• • Effective in Various Applications: Catalytic bead sensors are effective for monitoring ventilation systems, gas pockets, and confined spaces within mining operations.

5. Proven Reliability in Underground Mines

Underground mining operations face unique challenges when it comes to gas detection. Catalytic bead sensors have been proven time and again as the best technology for underground environments where line-of-sight detection is not always possible.

• • No Line-of-Sight Requirement: Unlike some infrared sensors, catalytic bead sensors don’t require a direct line-of-sight to detect gases, making them ideal for confined spaces and pockets where gas can accumulate unnoticed.
• • Predictable Failure Mode: If a catalytic bead sensor begins to degrade, the decline in sensitivity is gradual, allowing mine operators to detect and replace it before it becomes a risk.

6. Compliance with Safety Regulations

Mining safety regulations are stringent, and compliance is essential. Catalytic bead sensors are designed to meet or exceed the regulatory requirements for gas detection in hazardous environments.

• • Intrinsically Safe: Catalytic bead sensors are available in intrinsically safe models, certified for use in explosive atmospheres like those found in underground mines.
• • Meets Industry Standards: Catalytic bead sensors are widely accepted by organizations such as the Mine Safety and Health Administration (MSHA) and Occupational Safety and Health Administration (OSHA), ensuring compliance with safety standards.

Conclusion: Catalytic Bead Sensors are the Best Choice for Mining Gas Detection

In the mining industry, where safety is non-negotiable, catalytic bead sensors stand out as the best choice for combustible gas detection. Their ruggedness, accuracy, and versatility make them the ideal solution for mining operations exposed to harsh conditions, volatile gases, and strict safety regulations. Choosing catalytic bead sensors ensures that mining companies protect their workers, minimize risks, and remain compliant with safety standards.