When every second counts, there’s no room for lag
For project managers deploying connected systems in Zone 2 explosive atmospheres, finding networking equipment that meets both safety certifications and modern connectivity requirements shouldn’t be an obstacle to innovation.
The Challenge: When Safety Certification Limits Technology Choices
If you’re managing a project to deploy Internet of Things (IoT) sensors, thermal monitoring, or real-time analytics in refineries, chemical plants, or offshore facilities, you’ve likely encountered this frustrating reality: most advanced 5G routers aren’t certified by ATmosphères EXplosibles (ATEX) and most ATEX-certified equipment doesn’t support modern 5G networks.
This gap forces compromises that impact either safety compliance, network performance or project timelines.
The Modern Refinery’s Connectivity Requirements
Consider a common project scenario: deploying comprehensive thermal monitoring across a refinery to enable predictive maintenance and safety alerts.
A network of thermal cameras strategically positioned throughout process units and storage areas, paired with environmental sensors, creates a comprehensive monitoring mesh. The critical challenge isn’t just the cameras—it’s the network infrastructure that must connect them reliably and safely while maintaining complete operational control.
For security reasons, refineries typically deploy private 5G networks to ensure sensitive operational data never traverses public infrastructure. 5G technology offers compelling advantages for private network deployments: ultra-low latency enables real-time control and safety response for mission-critical applications. Equally important, 5G’s modern network core architecture provides a future-proof foundation that will remain current and viable significantly longer than legacy 4G networks, protecting infrastructure investments for decades to come.
Thermal monitoring is just one of many critical applications driving the need for secure and reliable 5G connectivity. Refineries also need predictive maintenance sensor networks that aggregate data from vibration sensors, pressure monitors and temperature probes across critical equipment to identify failures before they occur. Gas detection and safety monitoring systems require integration of detector arrays throughout the facility with intelligent threshold logic that can trigger immediate alerts. Many facilities also face the challenge of multi-protocol integration, needing to bridge legacy Modbus devices, modern Message Queuing Telemetry Transport (MQTT) sensors and analog inputs through a single certified gateway.
All of these applications require routing equipment that can:
- Handle high-bandwidth thermal camera feeds continuously in hazardous locations
- Process and filter sensor data locally to reduce latency and costs
- Operate in harsh conditions
- Support private network architecture and air-gapped on-premises management
The Solution: Semtech AirLink® XR60 ATEX-Certified 5G Router
The Semtech AirLink XR60 5G router is purpose-built for industrial environments. ATEX-certified for Zone 2 explosive atmospheres, it delivers industrial-grade 5G connectivity—supporting both public and private network deployments—without compromising on safety, security or performance. This industrial router serves as the critical infrastructure foundation—connecting thermal cameras, sensors and IoT devices while providing the intelligence, security and reliability that hazardous environments demand.
Key Benefits:
✓ Safety and Compliance
- ATEX certification (Directive 2014/34/EU) for Zone 2 explosive atmospheres
- Eliminates compliance risk and approval delays
✓ Flexible 5G Connectivity
- Multi-band 5G support for both public and private network deployments
- Low-latency, high-bandwidth connectivity for data-intensive mission-critical applications
✓ Edge Intelligence
- Built-in Linux container-based architecture for lightweight edge applications
- Reduce bandwidth and transmission costs through support for custom applications for data filtering, aggregation or protocol conversion
✓ Air-Gapped Management
- Flexible remote management options—cloud-based or on-premises
- Optional on-premises platform enables air-gapped operations with full local control of operational and monitoring data—never leaving your facility
✓ Industrial-Grade Reliability
- Ultra-rugged design for extreme temperatures, vibration and dust
- Five-year warranty for long-term total cost of ownership (TCO) confidence*
- Field-proven experience—trusted by all top 10 U.S. oil and gas companies
Implementation Example
A refinery deployed Semtech AirLink XR60 routers positioned at strategic points throughout the facility to create a robust private 5G network infrastructure.
Each XR60 router serves as a secure, intelligent gateway—connecting thermal cameras from Axis Communications and environmental sensors while maintaining complete network isolation.
Semtech’s on-premises management solution enables network administrators to configure and monitor devices entirely from the facility’s secure operations center—with no external internet access required.
With built-in edge computing support, the XR60 runs the refinery’s custom applications at the edge to:
- Filter thermal data: Process camera feeds locally, transmitting full-resolution frames only when temperature thresholds are exceeded
- Aggregate sensor readings: Collects data from multiple sensors, sending averaged values every five minutes but immediate alerts on anomalies
- Protocol conversion: Normalizes data from mixed sensor types (Modbus Remote Terminal Unit (RTU), MQTT, analog) into a unified format for the central Supervisory Control and Data Acquisition (SCADA) system
Planning for Safety-First Connectivity
This refinery’s experience illustrates a larger challenge for oil and gas organizations. The market for ATEX-certified industrial routers remains limited, making vendor selection critical.
For organizations planning similar deployments, several considerations emerge:
✓ Certification Scope: Genuine ATEX certification with appropriate documentation
✓ Network Architecture Flexibility: Support for both public and private 5G deployments with necessary frequency bands
✓ Management Options: Flexible management options, cloud or on-premises, to fit the requirements of your organization
✓ Edge Computing Capabilities: Built-in containerized applications support for custom lightweight applications
✓ Integration Requirements: Compatibility with your sensors, cameras and required protocols
✓ Implementation Risk: Partner with manufacturers who understand both networking technology and hazardous environmental requirements as well as provide proof of concept (PoC) validation opportunities
Ready to Evaluate the XR60 Router for Your Project?
Let’s explore how the XR60 fits your connectivity needs. Our team can help you evaluate your options—and offer hands-on PoC opportunities.
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Download our Resilient Communications for Oil & Gas: Strategies to Optimize Safety and Efficiency eBook
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