How do you integrated a gas pump into a suction-type multi-gas detector?

Are your diffusion-based gas detectors too slow? This delay puts workers at risk in confined spaces, where unseen hazards can be fatal. A gas pump is the answer.

A micro sampling pump is integrated into a multi-gas detector to actively draw air from a remote location. It connects via tubing to the detector's inlet, pulling a gas sample across the internal sensors, which allows for pre-entry testing and provides much faster response times.

Relying on ambient air to just drift over a sensor is a method that has always felt too passive for life-critical situations. The real advantage comes from actively sampling the environment before a person enters it. This is where a reliable micro gas pump transforms a standard detector into an essential safety tool. At BODENFLO, we build the pumps that make this possible. Let’s explore why they are so critical and how to choose the right one.

Why do you need a gas pump for a gas detector?

Are you waiting precious seconds for your gas detector to respond? In a hazardous environment, this delay can be the difference between a safe exit and a serious incident.

A micro pump transforms a passive, slow-reacting detector into an active sampling instrument. It allows you to test the air in confined spaces like tanks or manholes before entry, ensuring worker safety from a distance and providing faster, more reliable sensor readings.

I've been in the industry long enough to know that safety can't be left to chance. A diffusion detector¹ is fine for personal monitoring in an open area, but it's completely inadequate for confined space entry protocols. You simply cannot ask someone to enter a space to find out if it's dangerous. A suction-type detector², powered by a dependable pump, pulls the environment to you, giving you the critical data you need to make a safe decision. It’s a fundamental shift from reactive to proactive safety.

Diffusion vs. Suction-Type Detectors

This makes a pump-equipped detector the only professional choice for confined space work.

What makes a micro pump suitable for gas sampling?

Thinking any small pump will work for a gas detector? This is a dangerous mistake. A generic pump can fail, spark, or leak, leading to catastrophic failure and inaccurate readings.

A proper gas sampling pump must offer a long operational life, excellent air tightness, intrinsic safety (via a brushless motor), chemical resistance, and a stable flow rate. These features guarantee accuracy, reliability, and safe operation.

When designing pumps for gas detectors, safety and accuracy are non-negotiable. We obsess over the seals and diaphragm integrity because a tiny leak can dilute the sample, causing a toxic environment to read as safe. Furthermore, the pump motor is a major concern. A standard brushed motor can create a spark and has a limited life. This is why we recommend brushless DC motors³; they are spark-free and offer the long, maintenance-free life—up to 10,000 hours—required for safety equipment that must work perfectly, every time, for years.

Critical Requirements for a Gas Sampling Pump

Only a pump that meets these strict criteria should ever be considered for a gas detection application.

Why are the BODENFLO BD-05T01.5 and BD-05T02 ideal pumps for your detector?

Is your gas detector design compromised by bulky, unreliable components? This forces you to create a device that is heavy, has a short battery life, and requires frequent, costly servicing.

The BODENFLO BD-05T series is engineered for reliability and portability. With lifespans up to 10,000 hours, ultra-low power consumption, and a tiny footprint, this series is perfect for creating compact, long-lasting, and maintenance-free handheld gas detectors.

Engineers designing portable gas detectors face four key challenges: battery life⁴, size, weight, and long-term reliability⁵. We created the BD-05T series to master all four. The brushless motors are not only highly efficient, extending battery life, but they also offer exceptional operational lifespans of 8,000 to 10,000 hours. This translates to years of dependable service without maintenance. At the same time, these pumps are incredibly compact and lightweight—the BD-05T02500 weighs just 16.4 grams. This series gives you the choice between cost-effective brushed models for standard use and intrinsically safe, ultra-durable brushless models for critical applications.

BD-05T Series: Performance Specifications

At-a-Glance Comparison: Size, Lifespan & Key Advantages

This series provides a tailored, high-reliability solution for any gas detector design.

How does the pump's design impact battery life and device portability?

Is your portable detector's battery life a constant source of anxiety? A dead battery means downtime and compromised safety. A highly efficient pump is the key to maximizing runtime.

The pump is the main power consumer. An efficient brushless motor and smart PWM controls drastically cut energy use. A smaller, lighter pump also saves space, allowing for a bigger battery or a more compact, ergonomic design, directly improving runtime and user experience.

Think of the pump as the engine of your gas detector; its efficiency determines the device's "fuel economy." The single largest factor is the motor.

Our brushless motors in the BD-05T series are far more efficient than conventional motors, converting more electricity into airflow instead of wasted heat. This is why the BD-05T01.5 can achieve a 1.5 L/min flow while drawing only 0.4W. But efficiency isn't just about the motor. It's also about smart control. Using PWM speed control, you can run the pump at a lower speed for routine monitoring and ramp it up only when a fast sample is needed, saving significant battery life.

Finally, the pump’s size directly impacts portability. A tiny, lightweight pump like the BD-05T02 leaves more internal volume for a larger battery, giving you the best of both worlds: a compact device with an extended operational life.

Strategies to Extend Battery Life

By focusing on these three areas, we ensure our pumps help you build a better, longer-lasting portable device.

How do you properly integrate the pump into the gas detector circuit?

Have you selected the right pump but are unsure about the best way to integrate it? Improper installation can lead to leaks, flow blockages, and inaccurate readings, defeating the purpose of having a high-quality pump.

Proper integration involves creating a sealed air path from the sample inlet, through a filter, to the pump, and then across the gas sensors. Use high-quality, chemically resistant tubing like Viton or Tygon and ensure all connections are airtight to maintain the sample's integrity.

From my experience helping designers, I can say that the integration details are just as important as the pump itself. The first thing to consider is filtration⁸. A particle filter must be placed before the pump inlet to protect both the pump and the sensors from dust and debris. Second, the airflow path needs to be optimized. Keep tubing as short as possible and avoid sharp bends to minimize flow restrictions. Finally, think about control. The brushless models in the BD-05T series can be controlled via a PWM signal, allowing you to adjust the flow rate to conserve battery or to manage different sampling conditions, adding a layer of smart functionality to your detector.

Gas Detector Integration Checklist

Following these steps ensures your suction-type multi-gas detector operates reliably and accurately.

Conclusion

BODENFLO's micro vacuum pumps provide the intrinsic safety, leak-proof design, and long-term reliability required for modern gas detectors. To build a safer device, contact our experts at info@bodenpump.com.