Application Note 161205
SemeaTech Inc.
Three-Electrode Electrochemical Sensors
ABOUT SEMEATECH
SemeaTech is a worldwide leader in sensing technologies focusing on hazardous material detection in work
safety, occupational health and environmental protection to monitor toxic gases, such as CO, H2S, Cl2,
NH3, SO2, NO2, H2 and O3. Its product lines include the popular 4-series and 7-series industrial grade
electrochemical (EC) sensors using standard three electrodes that are
completely interchangeable in terms of form, fit and function with the
ones made by the other manufacturers in the marketplace. SemeaTech
delivers sensors with guaranteed quality in detecting ranges, stability,
linearity, repeatability, resolution as well as minimized cross-sensitivity.
FUNCTION PRINCIPLE
The three electrodes on an EC sensor are defined as R (Reference Electrode), S (Sensing Electrode) and C
(Counter Electrode) as shown below.
The EC sensor functions by reacting to the target gas and then producing an electrical output signal that is
proportional to the gas concentration. The target gas in contact with the sensor first passes through a
capillary-type opening and then diffuses through a hydrophobic barrier. It eventually reaches Sensing
Electrode surface. The molecules on the electrode are immediately oxidized or reduced to consequently
produce or consume electrons to generate an electric current. This is a catalyzed process based on the
electrode materials specifically developed for the target gas. For example, carbon monoxide is oxidized
at Sensing Electrode per following chemical equation:
CO + H2O →CO2 + 2H+ + 2e-
Counter Electrode works to balance out the reaction on Sensing Electrode. When oxidation occurs on Sensing
Electrode, oxygen is then reduced to form water on Counter Electrode. If it is reduction reactions on Sensing
Electrode, Counter Electrode then has reversible reactions accordingly. In this example water gets oxidized
per chemical equation as shown below:
½O2 + 2H+ + 2e- → H2O
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Application Note 161205
SemeaTech Inc.
And the overall reaction in this case is:
2CO + O2 → 2CO2
RECOMMENDED CIRCUITRY
The diagram above is a recommended circuitry for three-electrode EC sensors. It consists of three parts:
Potentiostatic Circuit, I/V (current/voltage) Converting Module and Short- Connected Configuration.
1. Potentiostatic Circuit
The potential difference between Sensing Electrode and Counter Electrode should not be smaller than a
specific value (depending on the type of sensor) to keep the sensor working normally. Reference
Electrode is positioned between Sensing Electrode and Counter Electrode physically in the sensor
mechanical structure. Correspondingly Reference Electrode potential should be between the potential of
Sensing Electrode and Counter Electrode in the current path. Under the combined effect of the
potentiostatic circuit of Reference Electrode and output circuit of Sensing Electrode, the potential
difference between Sensing Electrode and Reference Electrode is equal to the minimum value that keeps
the sensor working normally. As a result, the potential difference between Sensing Electrode and Counter
Electrode is not smaller than that minimum value in order to meet requirements for the sensor to work
normally.
The potentiostatic circuit is made up of U1A, R1, R2, R3, C1, C2, C3 and B1 (Ferrite bead). R1, R2 and
C3 together form the low-pass filter to reduce high frequency noise between Reference Electrode and
Counter Electrode; R2 and R3 are impedance matching resistors. Assuming U1A and U1B are ideal
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Application Note 161205
SemeaTech Inc.
operational amplifiers, VR is the potential of Reference Electrode, and VS is the potential of Sensing
Electrode. Consequently (VS-VR) is the minimum potential difference between Sensing Electrode and
Counter Electrode to keep the sensor working normally.
2. Measurement of Sensor Current
The output signal of three-electrode gas sensor is an electric current flowing through Sensing Electrode
and Counter Electrode. The best way to measure this current is to use I/V (Current/Voltage) converting
module that is made up of U1B, R5, R6, C4, C5, C6, C7, B2, R_Load and R_Gain. In most cases
(oxidation), the output current flows out from U1B and then flows into Sensing Electrode through
R_Gain and R_Load. The current is proportional to the concentration of target gas. Vo is the output signal
that can be calculated using the following equation:
Vo= ((I + Ibase)×R_gain) + VS (I = sensitivity × concentration)
Here,
i) Ibase is the output current while the concentration of target gas is zero (Ibase value can be found in the
sensor datasheet), and
ii) C4、C5、C6、C7、R5 and B2 are used for the suppression of signal noise. R6 and R7 act as impedance
matching the operational amplifier input.
3. Short-Connected Configuration
For unbiased sensors, Sensing Electrode and Reference Electrode should be short-connected when the
circuit power is switched off. This ensures that Sensing Electrode is maintained at the same potential as
Reference Electrode, ensuring that the sensor is ready immediately when powered on. The
short-connected configuration consists of Q1 and R4. Reference Electrode and Sensing Electrode are
connected with a P-channel transistor Q1 shorting the two electrodes at power-off state and opening them
during the power-on state.
Sensors that need a bias voltage don’t need such a short-connected configuration. In opposite, it is
recommended to hold the voltage (mostly 300 mV) all the time between Sensing Electrode and
Reference Electrode. This can be realized by connecting the sensor to a battery during power-off.
CONFIGURATION OF BIAS VOLTAGE
1. Biased
The bias voltage of corresponding sensors is shown in the table below.
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Application Note 161205
SemeaTech Inc.
Sensor Type Vbias
ETO +300mV(±10mV)
NO +300mV(±10mV)
C2H3CL +300mV(±10mV)
HCL +200mV(±10mV)
Oxygen -600mV(±10mV)
Notes:
i) When using biased sensors, the short-connected configuration is not needed. Therefore, Q1 and R4
should be removed in the circuitry;
ii) Vbias= VS – VR( VR and VS is provided by voltage reference IC).
2. Unbiased
For unbiased sensors, Q1 and R4 are required in the circuitry.
KEY POINTS FOR CIRCUIT DESIGN
1. Sensor Polarity
For reductive gas sensors, such as CO, H2S, SO2, PH3 and H2, the sensor output current flows out from
Counter Electrode functioning like “+” pin. After going through the external circuit it flows back to
Sensing Electrode which functions like “-” pin. For oxidative gas sensors, such as O2, NO2, CL2, CLO2
and HF, the sensor output current flows through the entire circuit the other way around.
2. OPA(U1)
The OPA should have very low input bias current on the inverting pin (U1B-6) and low input voltage
noise, such as OP07, OPA2378, MCP6V02.
3. Voltage Reference IC
The IC provides the fixed voltage for VS and VR. It requires high precision and low temperature drift
coefficient, such as LM285, REF3325, REF1112.
4. R_Gain
The sensor output current flows through R_Gain and then converts to voltage output signal. So it is very
important to select R-Gain with high precision and low temperature drift coefficient. The resistor value is
determined based on the sensor sensitivity and maximum measuring range (maximum load).
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Application Note 161205
SemeaTech Inc.
5. R_Load
R_load should be selected with the value between 10 ohm and 33 ohm. The higher resistor value is
selected, the better performance will be in noise reduction. However higher resistor value meanwhile
results the sensor in long response time to the target gas.
6. RC Filter
Connecting to U1-B output pin-7, a RC filter consisting of R5, C6 and C7 is recommended to add into
the circuitry. To stabilize the voltage output, the RC parameters need to be adjusted.
7. Filter Capacitor
C3, C4 and C5 are used as filter capacitors for better EMC performance.
8. VS Configuration
For reductive gas sensors, such as CO, H2S, SO2, PH3 and H2, VS should be set about 0.5V above earth
potential (0V) of the circuitry. VO increases while gas concentration increases. For oxidative gas sensors,
such as O2, NO2, CL2, CLO2 and HF, VS should be set about 0.5V below Vcc of OPA. VO decreases
while gas concentration increases.
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