Technical Note

1998-0690 Rev 1 06/06

The Next Generation of EC Sensors -
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SmartCELL

Honeywell Analytics manufactures flammable, toxic and oxygen gas sensors for use in a wide range
of markets. From low cost carbon monoxide detectors for domestic and commercial applications
through to high specification infrared point and open path flammable solutions for the oil & gas
industry Honeywell Analytics covers the widest possible range of sensing technologies coupled with
state of the art manufacturing techniques. Catalytic bead (flammable), electrochemical (toxic &
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oxygen), infrared (flammable) as well as Chemcassette paper tape (very low level toxic) technologies
are used to monitor over 100 different gases. This document focuses on the innovations within the
electrochemical based toxic gas sensing technology.

Introduction

Toxic gases may be monitored by a variety of different sensing technologies; these include
semiconductor, colorimetric paper tape, spectrophotometer and electrochemical. Some examples are
shown in Figure 1 below. Electrochemical sensors have proven most popular due to their low power
requirement, small physical size and relative low cost.

Figure 1 – Different Sensing Technologies

Due to the availability of a wide range of chemistries within electrochemical sensors they are used
throughout the world in a very wide range of applications. Ideally suited to monitoring toxic gases at
Occupational Exposure Levels (OELs) the sensors can be found in both portable and fixed gas
monitoring equipment measuring gases such as hydrogen sulfide and carbon monoxide; two of the
most common industrial gases found in the world.

Such toxic gases are used throughout the world. Due to their geographic locations or industrial
applications expected operation in extremes of temperature, humidity as well as gas level exposure
varies greatly. Not all electrochemical sensors are able to handle such a wide range of environmental
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conditions… until now. The SureCELL is an evolution of electrochemical technology coupled with
state of the art manufacturing techniques that now puts electrochemical cells at the forefront of the
market in detecting toxic gases such as hydrogen sulfide.
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Traditional Electrochemical Sensors
Figure 2 below shows a simplified view of a traditional electrochemical sensor comprising a housing,
filter and single large electrolyte between two electrodes. Some sensors incorporate a third electrode
(known as a bias electrode) which is not shown for simplification purposes. The housing, originally
metal but more recently made from plastic is filled with the electrolyte that reacts with the target gas to
produce very small currents that are picked up by the electrodes, amplified and then displayed via the
instrument being used.

Figure 2 –Conventional Electrochemical Cell

Such electrochemical sensors were used in harsh environments. The most extreme being found in the
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Middle East or Asia Pacific regions of the world. Extreme temperatures (55 C in the shade) or very
high humidity levels (>95%RH) are not untypical for significant portions of the year in these areas.

Early electrochemical sensors failed routinely in such environments for two reasons. First, in high
humidity levels water was absorbed by the electrolyte causing the unit to swell and expand. This
coupled with low volume, manual assembly production techniques which often resulted in
weaknesses in the housing resulted in cells that burst.

Market Leading SureCELLTM Design

Several manufacturers have improved upon the basic cell construction to try and improve
performance in harsh environments. However, Honeywell Analytics took a more radical approach by
re-designing the cell construction from the ground up and implementing the world’s first automated
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production line thereby removing random errors in manufacturing. By doing so the SureCELL has
proven itself in real life applications to have addressed the basic and fundamental problems faced by
other electrochemical sensors.
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Consider the radical new design of SureCELL shown in Figure 3.

Figure 3 –New SureCELLTM Design

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Still incorporating two or three electrodes (subject to chemistry and sensor type) the new design
incorporates two electrolyte reservoirs. The first, between the two electrodes shown, has a high
capillary action that draws the electrolyte from the second expansion or reservoir. In a similar fashion
to an old fashioned oil lamp the first reservoir never runs dry in low humidity applications. In areas of
high humidity, moisture absorbed by the electrolyte is pushed back into the second expansion
reservoir.

The take up and loss of moisture by the electrolyte is akin to the sensor breathing such that its lungs
never burst or dry out. Such an effect is much slower than that of breathing of course; however, the
ability of the sensor to operate in environmental extremes is vastly superior to any other
electrochemical device on the market.

Moisture Absorbed Moisture Released

Figure 4 - High Temperature / High Humidity Figure 5 - Low Temperature / Low Humidity
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The simplified plastic cell construction also uses 360 ultrasonically welded seals rather than gasket
compression seals as in old cells. The overall design reduces potential internal pressure due to
moisture absorption while ensuring the mechanical housing is strong enough to withstand any
pressures that may build up.

Automated Manufacturing is Key to Success

Consider the traditional cell manufacturers manual assembly process making 1000’s of sensors per
day. Complex sensor designs with multiple seals and gaskets that are all assembled by potentially
different shift workers at different times of the day. It is inevitable that such labor intensive approach
will lead to random errors in manufacturing. This hit and miss approach can lead to undiagnosed
batch issues such as imperfect seals (leaking cells) or worse premature cell failure in the field. Again,
Honeywell Analytics leads the field in implementing the world’s first automated manufacturing facility
to remove the random error and enable optimization of the process while minimizing controllable
systematic errors. ‘It’s not always what you do; it’s the way that you do it’.

Figure 6 – Automated Sensor Production Line

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The SureCELL production line is the world’s first fully automated production line for electrochemical
sensors with over 1 million cells produced to date. Sensors are used in both Honeywell Analytics
products and by OEM customers and are recognized for their high quality and reliability with less than
0.001% returns from the filed due to incorrect manufacturing; quality that is second to none in the
industry.

While cost reductions and increased volume potential are important the key benefit is the spread in
performance and operation is tightened and controlled through the elimination of human error. With
ALL sensors 100% tested, with gas, a database is used to record each and every one of 21 tests that
take place during the manufacture of any one cell; that’s over 300,000 tests per day that are fully
traceable to each and every bar coded sensor produced on the line.

The Real Benefits of SureCELLTM

The real benefits of the unique dual reservoir design, simplified cell construction and automated
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production process of the SureCELL electrochemical sensors is shown in Figures 7 though 9.
Fundamentally, through exacting controls in manufacturing Honeywell Analytics any systematic or
process deviations can be monitored. Where necessary corrections to process parameters can then
be adjusted to ensure sensor performance is consistent from cell to cell and batch to batch.

Effect of Humidity
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The unique breathing cell design enables SureCELL to operate in the widest humidity ranges
possible for any electrochemical cell in the market. At humidity levels >95%RH actual laboratory
measurements of humidity are difficult and inaccurate. As part of on-going life tests, sensors are
exposed to continuous near 100% RH environmental conditions to push the sensors to the limit.
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Conventional sensors routinely fail in environments slightly above 75%RH proving the SureCELL
dual reservoir approach offers significant advantages to other leading cell manufacturers.

Figure 7 – Effect of Humidity

Speed of Response and Temperature Performance

The cell construction with the two electrodes separated by a smaller reservoir with high capillary
acting wick for the electrolytes also improves the sensors response to gas and the effect of
temperature on the unit. This is shown in Figure 8 below.

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Figure 8 – Response Time & Temperature Performance

Consider the time for a sensor to react to the target gas. The T90 (time for the sensor to reach 90% of
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the target gas concentration) is shown above. At 20 C both conventional and SureCELL sensor
designs react in about 10 seconds. However, an electrochemical reaction is taking place and all such
reactions are affected by temperature. Generally, as the temperature is reduced the reaction slows
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down. However, the size of this effect is reduced when using SureCELL i.e. the variation seen
across the entire operating temperature range of a cell is less. Improved manufacturing tolerances
limits this variation from cell to cell thereby enabling consistent and accurate correction in software of
the final instrument the cell is used in.

Reduced Cross Interference

While re-designing the sensor construction Honeywell Analytics also took the opportunity to introduce
new and improved cross interference filters. These new and improved filters ensured that sensors are
as specific as possible to the target gas being monitored thereby reducing nuisance or unwanted
alarms.

Figure 9 – Reduced Cross Interference

Different filters are used in different sensors. Figure 9 shows the results for a carbon monoxide
sensor.

Summary

This document set out to demonstrate the marked improvements in electrochemical sensing
technology as employed by Honeywell Analytics in its wide range of commercial and industrial gas
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detectors. SureCELL electrochemical sensors are used in products marketed under various brands
such as Sieger, Neotronics, Lumidor, Sixth Sense, SF Detection and MDA Scientific. Fixed and
portable gas detectors are used throughout the world in many of the harshest environments be that
due to environmental conditions (temperature and humidity for example) or the process being
monitored.
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Honeywell Analytics Inc.

405 Barclay Boulevard
Lincolnshire, IL 60069

For more information

contact Honeywell Analytics’
Service Department during
normal business hours at:

800-323-2000
or 847-955-8200

24-Hour Emergency
Service Hotline:
847-634-2840

This publication is not intended to form the basis of a contract, and the company reserves the right to
amend the design and specification without notice

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